While pulling some corrective maintenance for some oil leaks, I decided to replace the distributor cap and rotor. Once I got her back together I started the engine and noticed that the idle was a bit rough. Surprise, I had screwed-up and swapped the #2 and #4 plug wires on the cap. After a quick correction and a re-start on the motor, I buttoned-up the rubber distributor cover. As I did so, I got a nice shock from the plug wires where they enter the cap. Didn't seem to matter where I put my hand on the cap; I'd get zapped again.

Surely my new cap wouldn't allow voltage leaks like that would it? I'm thinking my plug wires (original) are finally worn-out. The spec. limit is 25k ohms. According to my maintenance log, in April of '92 I measured the resistance (ohms) of the respective wires:

1. 13,000
2. 4,800
3. 15,000
4. 4,800
5. 16,000
6. 6,200

In April of '93 I again measured the same wires (ohms):

1. 15,200
2. 5,500
3. 17,700
4. 5,450
5. 19,200
6. 7,200

Being curious, I'm wondering if the wires have gone bad; possibly having a much higher (beyond spec.) resistance causing voltage leaks and me getting zapped. [Edit] August 13, 2013 resistance values (ohms):

1. 19,000
2. 8,600
3. 22,000
4. 8,600
5. 24,000
6. 10,000

Maybe the cause is that the new Import Direct cap is a POS and my wires are fine, or maybe it's both. Anyway, I'll edit the new resistance measurements tomorrow. Any one else get zapped by their distributor cap or plug wire cap boots? I have not used dielectric grease for the plug boots before. Is this situation a good reason to use the grease on new plug wire boots?

New part brand/model:
Distributor rotor: Import Direct #12-0184
Distributor cap: Import Direct #10-0221

 

How much you pay for your cap and rotor ?

 

Cap was $12.99, rotor was $7.99 from O'Reilly Auto Parts

 

Not bad, if you need wires check out Rockauto.

Denso's for $25 or NGK's for $50
http://www.rockauto.com/catalog/x,ca...,parttype,7224

 

Thanks Big Bear. Hope the area you're at is still nice. I used to live in Apple Valley not far from you.

 

Gets a little toasty about this time of the year in AV.

I love BBL, just have to deal the the invasion of flatlanders on the weekends and holidays. Their brains don't work well at high altitude,hehe.

Up where you live now is pretty nice, used to go up to Port Townsend in the late 80s.

 

All my plug wires show increasing resistance values over their lifespan (see data). #5 is getting close to the specification limit of 25k ohms.

Is this resistance causing the voltage leaks? Should I use dielectric grease? And/or is my new distributor cap a POS?

Thanks all in advance,
-Eric

 

Plug wires should be replaced ever so often. If you're running originals from 93, then you need new wires anyway.

Strangely enough, my new distributor zaps me too. That's with new wires on it (2 years I guess) and a new cap and rotor (1 year). Maybe I should replace mine, not like it's pricey or anything.

 

Hey Game,
Yeah, I was trying figure-out why I was getting zapped as I don't recall ever getting shocked through the cap/wire boots before. There's got to be a reason I think.

 

I'm guessing it's my cap and rotor, but it runs great so I don't really mind. I just don't touch the distributor when it's running!

 

I just ordered cap, rotor and o-ring from Rockauto, Beck Arnley.
$20 shipped.