What would cause an ignition control module to fail?
The cause of an ignition control module failure is often associated with age and damage from heat buildup. The correction for this issue becomes the replacement of the failed component.
You are entering the next phase of the investigation. So far there have been a lot of good observations about the design and construction of the modules. Some good techniques have been noted for disassembly. Lots of speculation about what the problems are. Now it is time to figure out exactly what is causing the failures.
As Pishta has said, often the failures are the same parts, usually the parts that see the most stress. In a mechanical system, that is usually the moving parts that fail. In an electrical system it is often the parts that see the most voltage or current. That is a great place to start, However, it is just a theory until you find the failed parts. The failures could be the same part, or it could be something different on each one.
Once you find out what is failing, then the discussion about design improvements can really start.
