Mallory Ignition 502m User Manual
FORM #1263M (REV. F) 01/01
®
INSTALLATION INSTRUCTIONS
UNILITE® BREAKERLESS IGNITION
CONVERSION KIT
1957-74 FORD/MOTORCRAFT 8-CYLINDER
SINGLE POINT DISTRIBUTORS
PART NO. 502
IMPORTANT: Before starting the installation of the UNILITE® Ignition System, make sure that the vehicle is equipped with an ignition
ballast resistor (or loom resistance wire) in the wire between the ignition switch and the coil (+) terminal. One easy way to find the
ignition ballast resistor is to check the service manual for your vehicle. You can test your stock ignition system voltage while the
engine is at idle at the coil (+) terminal. If the measured voltage is within 1 volt of battery voltage, an ignition ballast resistor must be
installed in the wire from the ignition switch. Example: Vehicles with a Ford TFI or Delco HEI require adding an ignition ballast resistor
in the wire from the ignition switch. If you find your vehicle is not equipped with an ignition ballast resistor, install a Mallory Ignition
Ballast Resistor Part No. 700 in series in the wire from the ignition switch. Failure to use an ignition ballast resistor will result in the
eventual destruction of the UNILITE® Ignition Module. Exception: If your vehicle is equipped with a HYFIRE® Electronic Ignition Control or
similar aftermarket ignition control, use ignition ballast resistors and wiring procedures as stated in the instructions for the particular
ignition control.
NOTE: This kit can be installed in the distributor without removing the distributor from the engine if the distributor is
easily accessible. However, removal of the distributor from the engine is recommended.
LIST OF PARTS:
1 UNILITE® Module Part No. 605
1 Rotor/Shutter Wheel Part No. 333
1 Distributor Wire Harness Part No. 29349
1 Female connector
1 Upper mounting plate
GENERAL INFORMATION
IGNITION COILS
The UNILITE® Ignition System is designed to work with most stock ignition coils
and aftermarket high performance ignition coils. For optimum performance,
use a Mallory PROMASTER® Coil Part No. 29440 or 29625, or Mallory
Chrome Electronic Ignition Coil Part No. 29216.
SPARK PLUG WIRES
To prevent false triggering and the possibility of premature ignition failures, use
suppression-type spark plug wire. We recommend spiral core ignition wire,
such as Mallory PRO SIDEWINDER® Ignition Wire.
1 Lower mounting plate
2 Screws, 6-32 x 3/16"
2 Flathead screws, 8-32 x 1/4"
1 Flathead screw, 8-32 x 3/8"
1 Capsule, white silicone grease
1 Grommet
ELECTRIC WIRING
Unplug the distributor wire harness before welding on the vehicle.
OPTIONAL ACTIVE POWER FILTER PART NO. 29351
Voltage spikes (voltage transients, power surges) are associated with noisy
electrical systems from electrical defects such as worn alternator brushes,
corroded or oxidized electrical connections and similar electrical problems.
This device protects the UNILITE® Ignition Module against voltage spikes.
SPARK PLUG GAPS
For street applications, use your engine manufacturers specifications. For
racing applications, start with your engine manufacturers specifications, then
experiment with and closely monitor various gaps to achieve maximum
performance.
1
INSTALLATION PROCEDURE
Step 1
Disconnect the point trigger wire from the coil () terminal.
Step 2
Locate the #1 cylinders spark plug wire on the distributor cap. See a service
manual for these locations. Mark the distributor cap and the distributor
housing, in line with #1 cylinders spark plug wire position on the distributor
cap.
Step 3
Turn the engine crankshaft in the direction of rotation until the timing mark lines
up with the top dead center (TDC) mark on the timing tab. See a service
manual for these locations. NOTE: Removing the spark plugs may make it
easier to turn the crankshaft.
Step 4
Remove the distributor cap from the distributor and lay it aside. Do not remove
the spark plug wires or coil wire. The rotor blade should point to the mark
made on the distributor housing (from Step 2). If it is not, turn the engine
crankshaft in the direction of rotation one full turn (repeating Step 3) until the
timing mark lines up (again) with the TDC mark on the timing tab. NOTE: Once
you are finished with Step 4, DO-NOT turn the crankshaft until the UNILITE
Conversion Kit and distributor is installed (Step 12).
Step 5
Note the direction the rotor is pointing. Note the direction the vacuum chamber
is pointing. Remove the distributor hold down clamp and remove the
distributor from the engine.
Step 6
Remove the rotor. Disconnect the primary point wire. Remove the primary
wire and the grommet from the distributor. Remove the breaker point and the
condenser from the breaker plate. Install the ground wire to the breaker plate
using the condenser screw.
Step 7
Position the lower mounting plate (with one countersunk hole) against the
breaker plate. Align the countersunk hole over one existing breaker plate
threaded hole. Align one non-threaded hole with the other breaker plate
threaded hole. Install one 8-32 x 3/8" flathead screw through the nonthreaded hole (temporarily, do not tighten) to help in the alignment of the lower
mounting plate onto the breaker plate. Install one 8-32 x 1/4" flathead screw
through the countersunk hole and tighten firmly into the breaker plate.
Remove the 8-32 x 3/8" flathead screw.
Step 8
Position the upper mounting plate with its countersunk holes aligned with the
holes in the lower mounting plate. Install one 8-32 x 3/8" flathead screw
through the non-threaded hole in the lower mounting plate into the breaker
plate. Install one 8-32 x 1/4" flathead screw into the threaded hole in the lower
mounting plate. Make sure to tighten these screws firmly.
Step 9
Apply a thin coat of white silicone grease to the bottom of the UNILITE® Module.
Install the UNILITE® Module onto the upper mounting plate with two 6-32
screws. Make sure to tighten these screws firmly.
Step 10
The grommet has a flat on one flange. Install the grommet in the hole in the
distributor housing where the primary wire had previously fed through with the
flat on one flange facing out and up. Positioning the flat on one flange facing out
and up allows adequate distributor cap clearance. Slide the three wires from
the UNILITE® Module, through the grommet, to outside the distributor housing.
Step 11
Put the UNILITE® Modules three wires in the female connector:
GREEN WIRE in hole #1
BROWN WIRE in hole #2
®
RED WIRE in hole #3
Plug the female connector into the distributor wire harness. See Figure 1.
Step 12
Install the rotor/shutter. Place the distributor in the engine with the rotor pointing
in the same general direction as during removal of the distributor (from Step 5).
NOTE: The distributor must be fully seated into the engine. It may be
necessary to turn the oil pump drive, or turn the engine crankshaft in the
direction of rotation two full turns until the timing mark lines up (again) with the
TDC mark on the timing tab to allow the distributor to seat fully.
Step 13
Rotate the distributor housing until the rotor points to the mark on the distributor
housing (from Step 2) and the nearest slot on the rotors shutter wheel is
approximately in the center of the optics of the UNILITE® Module. This will
generally put timing close enough for starting purposes. Put the distributor hold
down clamp in place and tighten slightly, leaving it loose enough to turn the
distributor housing.
Step 14
Install the distributor cap. NOTE: The grommet was installed during step 10.
The grommet has a flat on one flange. When installed, the flat on the flange of
the grommet must face out and up to allow adequate distributor cap clearance.
The distributor cap may not sit properly on the distributor housing unless these
details are followed exactly.
FIGURE 1
2
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