Burns a hole in distributor rotor - 1996 Dodge Ram 1500 Club Cab

I have encountered this only a few times and none of the events could be applied to your vehicle except for the one below. The last time was caused by shorted turns in the coil primary creating a massive spark which was interesting. At night the underbonnet looked like an electrical storm.

I suspect in your case the distributor shaft has a slight bend or excessive wear in a bush causing it to wobble and wear the hole in the rotor tab rather than burning it through. Once the smooth surface has disappeared the carbon pip wouldn't last very long.

I suggest you check for run-out and bearing play with a dial indicator and allow a maximum of 0.003 inches. More than that and remedial action will be needed.

Two different things can cause this problem. (1) The ignition rotor has a hole burned in it to ground the fire or, (2) the distributor is not spinning due to a bad drive gear or sheared pin. The ignition rotor is more common failure but, the sheared pin or gear is likely. If the gear or pin is damaged,make sure the oil pump is not locked up. The oil pump is driven by the distributor when it is turned by the camshaft.

distributor shaft bushing worn out.

#1 plug is closest to the front. Take off distributor cap. Remove #1 plug. You want to crank engine until #1 cylinder is on compression stroke. Watch to see direction the distributor rotor is turning. As the compression stroke starts then bring the engine to top dead center by aligning timing mark on crak shaft pulley with pointer. The #1 plug wire goes in the distributor cap hole the rotor is pointing. The #2 wire in the next hole following the direction the rotor turned. Then the #4 wire and finally #3. Firing order 1-2-4-3.

No. 1 cylinder. Reinstall the spark plug and wire.3 Install the distributor, making sure the gasket is in place, and with the rotor facing the No. 1 cylinder. With the curvature of the gear on the distributor and camshaft, the rotor will turn about 30 degrees when meshed. Place the distributor shaft in the hole, but hold the distributor high enough so that it does not contact the gear. Point the rotor toward the No. 1 cylinder, then rotate it counterclockwise about 30 degrees and insert the distributor. If the rotor does not point in the right direction yet, lift the distributor and turn the rotor a little farther and insert it again until it points to the No. 1. If the rotor keeps lining up wrong, remove the distributor all the way, and insert the long screwdriver in the hole. Turn the oil pump drive a little, then try the distributor again.4 Install the distributor hold-down clamp and bolt. Loosely tighten the bolt so the distributor can still be turned.5 Rotate the distributor so that the vacuum advance, if there is one, is an equal distance from the firewall and the carburetor. Lay the distributor cap on, and pay attention to a spark plug wire terminal location in relation to the rotor. Once you've found a spark plug terminal that is very close to the rotor end, make a mark on the distributor housing directly below the center of the terminal location. Remove the cap, and rotate the distributor housing so the mark just made is exactly under the rotor end. Move the distributor housing counterclockwise another 5 degrees, and tighten the distributor hold-down bolt with a wrench.6 Install the distributor cap, paying attention to which terminal the mark is under and which terminal is closest to the rotor end. Use a screwdriver to tighten the hold-down screws on the cap.7Install the No. 1 spark plug wire in the terminal in front of the rotor end. Install the remainder of the wires in a clockwise direction using the firing order 1-8-4-3-6-5-7-2.

Misfires across all 6 cylinders could indicate the following:


Priority Action Part Type Cause 1 Inspect Wireset Worn, Damaged or Faulty Spark Plug Wire(s). 2 Inspect Distributor Cap Loose, Burned or Cracked Distributor Cap. 3 Inspect Distributor Cap and Rotor Kit Loose, Burned or Cracked Distributor Cap and Rotor. 6 Inspect Spark Plug Fouled, Damaged, Broken, or Incorrectly Gapped Spark Plug(s). 7 Inspect Coil - Ignition Faulty Ignition Coil. 8 Inspect Condenser-Ignition Faulty Condenser-Ignition. 9 Inspect Point Set Burned, Worn or Incorrectly Set Ignition Points. 15 Inspect Timing Specification Incorrect Ignition Timing. 19 Inspect Fuel Injector Dirty or Worn Fuel Injectors. 21 Inspect Intake Manifold Gasket Leaking, Worn, or Damaged Intake Manifold Gasket. 22 Inspect Distributor Worn, Damaged or Faulty Distributor. 24 Inspect Valve Burned, Worn, or Sticking Exhaust Valves.

First verify if you have spark using a tester,then verify you have fuel
now verify timing heres how;

To get #1 compression remove plug and put your finger in the hole and have someone crank the engine until you feel your finger being pushed off by the air pressure. Now line up the timing mark.

Rotate the number 1 cylinder to Top Dead Center (TDC) of the compression stroke.



Align white paint mark on the bottom stem of the distributor, and the pre-drilled indent hole in the bottom of the gear (3).
Notice: The ignition system distributor driven gear and rotor may be installed in multiple positions. In order to avoid mistakes, mark the distributor on the following components in order to ensure the same mounting position upon reassembly:

• The distributor driven gear

• The distributor shaft

• The rotor holes

Installing the driven gear 180 degrees out of alignment, or locating the rotor in the wrong holes, will cause a no-start condition. Premature engine wear or damage may result.

Notice: Installing the driven gear 180 degrees out of alignment, or locating the distributor rotor in the wrong holes, may cause a no-start condition. Premature engine wear and damage may result.

With the gear in this position, the rotor segment should be positioned as shown for a V6 engine (1) or V8 engine (2).
- The alignment will not be exact.

- If the driven gear is installed incorrectly, the dimple will be approximately 180 degrees opposite of the rotor segment when it is installed in the distributor.





Using a long screw driver, align the oil pump drive shaft to the drive tab of the distributor.
Guide the distributor into the engine. Ensure that the spark plug towers are perpendicular to the centerline of the engine.



Once the distributor is fully seated, the rotor segment should be aligned with the pointer cast into the distributor base.
- This pointer may have a 6 cast into it, indicating that the distributor is to be used on a 6 cylinder engine or a 8 cast into it, indicating that the distributor is to be used on a 8 cylinder engine.

- If the rotor segment does not come within a few degrees of the pointer, the gear mesh between the distributor and the camshaft may be off a tooth or more.

- If this is the case, repeat the procedure again in order to achieve proper alignment.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Install the distributor mounting clamp.

Tighten
Tighten the distributor clamp bolt to 25 N·m (18 lb ft).





Install the distributor cap.
Install two NEW distributor cap screws.

Tighten
Tighten the screws to 2.4 N·m (21 lb in).

Install the electrical connector to the distributor.
Install the spark plug wires to the distributor cap. Refer to Spark Plug Wire Harness Replacement
Important: If the Malfunction Indicator lamp is turned on after installing the distributor, and a DTC P1345 is found, the distributor has been installed incorrectly.
Repeat Installation Procedure 2 for proper distributor installation 
hope this helps

Hi, no there are not any holes in the cap. There is a gasket that runs around the distributor to keep out the moisture. Change it out, this must be dry and you know that. It has to be the gasket as if the cap was cracked it would run very poorly. Check and replace the gasket.
Sincerely,
Shastalaker7

Firing order is 1342. #1 cylinder is closest to front. (By pulleys)



See Figures 1, 2, 3 and 4
Engine Not Rotated

1. Disconnect the negative battery terminal.
2. Turn the engine over until No. 1 cylinder is at TDC of the compression stroke.
3. Remove the distributor cap. Remove the wire harness connected to the side of the distributor.
4. Mark the position of the distributor base in relation to the engine block with white paint or other suitable marking material, for reference when reinstalling the distributor.
5. Loosen and remove the distributor hold-down bolt and clamp.
6. Carefully begin lifting the distributor up and out. Once the shaft is clear of the engine compartment, inspect the shaft for cracks in the O-seal, the condition of the shaft drive gear and any other part which could lead to distributor problems in the future.

To install:

1. Check to make sure the engine is still at TDC. Inspect distributor shaft hole to make sure it is free of dirt.
2. Rotate distributor shaft until the painted mark on rotor is pointing toward painted mark on engine block made during removal.
3. Continue rotating rotor slightly so leading edge of the vane is centered in vane the switch stator assembly.
4. Dip entire distributor gear in engine assembly lubricant D9AZ-19579-D or equivalent.

If installing a new distributor, ALWAYS add engine assembly lubricant to the engine oil by pouring it through distributor hole onto the camshaft gear. Run engine at idle for at least five minutes before driving.

1. Rotate distributor in block to align leading edge of vane and vane switch stator assembly. Verify rotor is pointing at No. 1 mark on distributor base.

If vane and vane switch stator cannot be aligned by rotating distributor in cylinder block, remove distributor enough to just disengage distributor gear from camshaft gear. Rotate rotor enough to engage distributor gear on another tooth of the camshaft gear.

1. Install the distributor retaining bolt and tighten so the distributor can just barely be moved.
2. Install the distributor cap and, tighten screws to 18-23 inch lbs. (2.0-2.6 Nm).
3. Reconnect battery cable. Start vehicle, and check timing. If timing needs adjustment, refer to the Ignition Timing section.
4. After timing has been set, tighten distributor hold-down bolt to 17-2 ft. lbs. (23-34 Nm).

Engine Rotated with Distributor Removed

1. If the crankshaft was rotated while the distributor was removed, the engine must be brought to TDC on the compression stroke of the No. 1 cylinder.
2. Remove the No. 1 spark plug. Place a finger over the hole and rotate the crankshaft slowly in the direction of normal rotation until engine compression is felt.
3. When engine compression is felt at the spark plug hole, indicating that the piston is approaching TDC, continue to turn the crankshaft until the timing mark on the pulley is aligned with the 0 mark on the engine front cover.
4. Turn the distributor shaft until the ignition rotor is at the No. 1 firing position.
5. Rotate distributor shaft so the blade on rotor is pointing toward paint mark on distributor base made during removal.
6. Continue rotating rotor slightly so leading edge of the vane is centered in vane switch stator assembly. Verify rotor is pointing at No. 1 mark on distributor base.

If vane and vane switch stator cannot be aligned by rotating distributor in cylinder block, remove distributor enough to just disengage distributor gear from camshaft gear. Rotate rotor enough to engage distributor gear on another tooth of the camshaft gear.

1. Install the distributor retaining bolt and tighten so the distributor can just barely be moved.
2. Install the rotor and distributor cap and connect all wiring. Tighten distributor cap to 18-23 inch lbs. (2.0-2.6 Nm).
3. Reconnect battery cable. Start vehicle, and check timing. If timing needs adjustment, refer to the Ignition Timing section.
4. After timing has been set, tighten distributor hold-down bolt to 17-2 ft. lbs. (23-34 Nm).

The rotor is somehow making direct contact with one or more distributor contacts.

Check the contacts inthe cap to see if you find any physical damage to one or more contacts caused by the rotor.

Could be rotor lead too long (file it down) or maybe the distributor shaft is bent or not seated. Remove cap and observe the distributor shaft as someone cranks the engine. Does it wobble? Can't tell? Place a stiff reference parallel to the shaft and turn engine again.