Why do the ignition boxes fail?

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So I heard back from the RT garage on what coil and ballast resistor they were selling. Their recommendation for the revnnator for resistance on coil was 1.5 ohm and ballast 1.0. So I’m guessing that means that’s what they were selling at the time. Based on that, I should be good with the Hi Rev.
 
I think you have to remember that demand for older electrical components, etc has dropped so the number of manufacturers has too . Nowadays you get what you get as far as quality goes.
 
I think you have to remember that demand for older electrical components, etc has dropped so the number of manufacturers has too . Nowadays you get what you get as far as quality goes.
If that's the case, when you buy an MSD ignition, a hot blonde should come with it, install it for you, give you a happy ending and then LEAVE.
 
SOB his alt was putting out 17VDC only under load. That was the issue. So that was a weird one.
There you go..:) The killer of so many electronics, over voltage, power spikes & inconsistent supply. Would probably fry any sort of ignition module.

A 17VDC coil supply would spike the secondary/H.T voltage up pretty high. The reflected ‘fly back’ after a spark event would be pretty high as well.
 
So from the sound of it, ignition boxes fail most from stupidity.
 
I do think the Hi Rev is the better one you can get now. Only heard of one fail but the guy was also running a .6 ohm coil. Remember also a chrome box or orange box aftermarket are definitely not the same *** a Mopar one. They basically are a stock box. Just helped a member over at FBO out he was killing coils. Weird one we went through his system could not find a thing. Sent him a tester Rob same as you have. Nada found. Hey rev it up and put a load on it with lights. SOB his alt was putting out 17VDC only under load. That was the issue. So that was a weird one.

So I’m looking at Mancini. They have an orange box, a black box, and then this Mopar Performance orange one. So the MP is not the same as the stock orange box?
Mopar Performance - Electronic Control Unit
 
Nope Authorised for mopar. Also that is a cover not a transistor. You will be hard pressed to find a old orange NOS box under 200 now.
 
So I’m looking at Mancini. They have an orange box, a black box, and then this Mopar Performance orange one. So the MP is not the same as the stock orange box?
Mopar Performance - Electronic Control Unit
I just went through this with VRs. I like Mancinci and have ordered from them many times. However, check reviews on these. Most are not Mopar; they are not even printed on, just stickers. They are the same junk ones people are having issues with. I suggest you contact Hoppy @halifaxhops and get one from him. He has NOS or ones he tests and will stand behind what he sells. It says on Mancinci returns, no returns on electronics.
 
From experience it seems that poor quality components are the main offenders (other than bad grounds). Moisture doesn't seem to be an issue since the components are completely sealed.
I agree, always check for a good ground before looking deeper. This also goes for our new cars with computers. Most issues are due to faulty grounds.
 
I would be interested in trying an autopsy if anyone wants to send me a dead ignition module. My guess is that the original power transistor is no longer made and they've either grabbed a different part that didn't quite meet a key specification, or resorted to chip brokers who buy up obsolete parts but sometimes grab batches that haven't been stored properly (or worse).
I’d be interested in knowing what percentage of boxes you receive are functional.. lol
 
I burned out a High Rev in my Charger.

View attachment 1716405918

View attachment 1716405919

I had the 1.4 ohm coil and the .70 Ballast resistor.

View attachment 1716405920

The instructions with the distributor, Hi Rev ECM and ballast:

View attachment 1716405922

I have had crappy luck with ECMs though. Last year I was dealing with a battery that would drop voltage. The battery would be okay to start the engine but it had me wondering if (when running and recharging the battery) the charging system somehow wreaked havoc with the ignition system. I wasn't sure if the ignition system was sensitive to the voltage fluctuations.
I admit to being borderline clueless to electrical matters sometimes.
I think you have the washer at the wrong location. Should be touching the body for a good ground. If you were looking for a lock washer, it is different.
 
I'm late to the game so sorry if this was already mentioned...

but typically in aftermarket these "transistors" (yellow) are fake

And the "heatsink" (green) may or may not be functional


Someone posted shots of the insides of one of these once.

Screenshot_20250517-080830.png
 
A quality ECU will have a transistor that will look something like this. This one happens to be a Filko brand and has a RCA transistor. The old Mopar boxes used RCA, Motorola, and later I have seen STI transistors.

20250405_130643.jpg


20250405_130703.jpg
 
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That size transistor is called a TO-3. I checked with the usual electronics component sources for TO-3 sized transistors, whether they're suitable for an ignition module or not. (As others have noted, there's a lot of power supply or audio amplifier transistors that won't fit the voltage demands even if they're in a big, well cooled case.) I came up with a few that were priced at $10, obsolete, and when they're gone, they're gone. And some others that were priced at $50 each. As for the original manufacturers: RCA was sold to General Electric, who used to make transistors but dropped that side of the business before they bought RCA. Motorola's semiconductor line spun off as Freescale and was acquired by NXP, who continues many of their chips but hasn't been making individual transistors.

If you want to make a module that looks like the originals, and sell it at a reasonable price, you can either dredge up obsolete parts from dead inventory that was sitting in somebody's warehouse that they no longer needed, or throw a fake cosmetic transistor on there.

There are a lot of more contemporary transistor designs out there that make less heat and shed it quite well, but they call for their own approach to heat sinking. Bolting something like a TO-220 or TO-247 to the back of that heat sink from inside the case would get you something close to the original look; you may even be able to use one of the bolts that holds the TO-3 in place. Or you could ditch the stock appearance, design the circuit around something that would properly drive a modern IGBT or similar transistor, and design the mechanical bits based on what heat sinking your new circuit needs.
 
I think you have the washer at the wrong location. Should be touching the body for a good ground. If you were looking for a lock washer, it is different.

I’d be surprised if grounding were an issue. The paint around the mounting holes was scraped off good.
Who knows though.
 
I had an issue with control boxes. Mine was the blue wire going to the voltage regulator was compromised in the harness at the solder joint where all the blue wires are connected under the tape near the bulk head. This cause over charge spike but not consistent. So unless your watching the Amp. gauge you may miss the spike. Bad ground on the regulator will also cause this. Or Dirty blue wire connection at the bulk head.
This right here Steve and his son do all of their own work and are a talented family.
 
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