Mallory Ignition Mallory Distributor Gear/Coupling - Manual

Distributor Gear/Coupling Instructions
Some Mallory distributors and magneto bases are not
equipped with a drive gear or coupler. If your original
distributor is equipped with a drive gear or coupler and the
Mallory distributor is not, remove the gear or coupling from
the original distributor and install it on the Mallory
distributor. Follow the instructions listed below.
Step 1
Remove the gear or coupler from the OEM distributor by
pressing or punching out the roll pin.
NOTE: Remove and retain the thrust washer located just
above the gear/coupler.
Step 2
Grasp the Mallory distributor or magneto base at the hous-
ing and pull down on the shaft to remove all slack
(Figure 1).
Step 3
Install the OEM thrust washer and gear/coupler onto the
Mallory distributor or magneto by sliding them onto the
shaft. Push on the shaft from above while holding the thrust
washer and gear against the housing to remove all slack
(Figure 2).
Step 4
Pull the gear/coupler away from housing enough to insert a
.020” feeler gauge (Figure 3). After inserting feeler gauge,
press on both ends of distributor or magneto to remove all
slack.
Step 5
Using the hole in the OEM gear/coupler as a guide, drill a
hole through the Mallory shaft using a drill bit the exact size
of the hole in the OEM distributor shaft (Figure 4).
NOTE: Ensure that all slack is removed and feeler gauge
remains in place while drilling. We strongly recommend
using a drill press for this procedure.
Step 6
Press a new roll pin (the same size as the OEM pin) into
gear/coupler shaft. Remove the feeler gauge. The gear/cou-
pler should be pinned to the shaft and the gear should move
.010” to .030” relative to the housing.
FORM 854 04/05
INSTALLATION INSTRUCTIONS
1 MALLORY IGNITION www.malloryracing.com
FIGURE 1
FIGURE 2
PULL ON SHAFT TO
HOLD ONTO HOUSING
OEM THRUST WASHER
OEM GEAR OR COUPLER
HOLD ONTO GEAR
PUSH ON THE SHAFT