Hi guys

I previously posted "TFI replacement 4 x in as many years"
post1447553.html?hilit=TFI#p1447553

Well its done it again and I'm just getting so tired of this. Last time was a new Bosch TFI. Its done 16 months 10,000km and was fitted with a new coil and cap at same time. All the leaks (radiator and oil) were fixed prior to fitting. Driving home other night and engine dies going up a hill. Pretty sure its TFI again. No way heat was an issue as it was cold weather (under 10 deg) and car only running 10 mins from cold. Is there something else that could be causing the TFI to blow repeatedly?

Are you putting heatshink paste onto the mating surfaces when installing the module ?
Otherwise check the the earthing on the engine.
Inspect the lugs on the earth cable for corrosion.
I would even go to the extent of unbolting the lugs, cleaning and then re-bolting.

Remembering that in the US, they moved the TFI off the engine for reliability.

Hi, yes been applying the paste to the new TFI mating surface. I just fixed it again the other day. Was definitely the TFI again as that was all I changed. I've looked at mounting it remotely but just not enthused to try it even though I have old TFI's to make connector. I just can't believe I cant get 10k out of a TFI. Will check the earthing if you think that will effect it.

OK, paste applied so not that.
There are about 7 amps being switched by the TFI so a lot of heat from the switching transistor.
Should not need to mount remotely all things being correct.
If you do mount remotely, make sure it is onto a good heatsink (e.g. Jaycar HH8566 or similar).
Have not done that myself, but, methinks it would need something like that as it is dissipating around 100 watts.

If you look on Ebay you'll probably find the Genuine Ford Remote Mount Heatsink.

There were Lawsuits in the US, due to the way these failed. its not normally an issue on an I6, but if youve changed it (Cams, Exhaust, Tuning) then you may be changing the Physical Wear Environment for the TFI

check charging is not to hi.

take numbers from current TFI module and current coil to place of purchase and have them verify that it's the correct coil to suit the module as it,s current draw may be to hi,google may also achieve this .
A faulty earth to engine may be causing vehicle to try and find better earth thru module earth so worth at least checking.