'GB'ird (12/1/2010)
......Presumably there are more teeth on the drive cog than flats on the hex, so is it possible to be a tooth out of sync? I got TDC (I think - difficult to tell with the tiny marks on the pulley) but the dist only fully engages with the rotor pointing between #5 and #1. Can't seem to get it in anywhere else. Tried starting it and it splutters a bit but won't fire up.Very rarely does the distributor drop all the way in without having to rotate the engine either slightly forward or backwards so that the oil shaft aligns with the distributor. And its not unusual to be just one tooth off where the vacuum advance chamber on the distributor is situated such that distributor movement is inhibited in the right direction. In the case of being just a tooth off, the distributor is pulled up and moved one tooth which typically requires that the engine (crankshaft) will need to be moved one way or the other to realign the oil shaft once again.
My preferred method of dropping in the distributor is to first insure that the engine TDC is on the #1 compression stroke. I then move the crank so that the damper is on 15° BTDC at the timing mark. With the distributor case marked with a Sharpie where #1 on the cap is suppose to be, I then drop the distributor in with the rotor pointing approximately at that #1 Sharpie mark. If the distributor does not drop all the way down due to the oil shaft, then I simply rotate the engine forward or backwards with a light downwards pressure on the rotor until the distributor falls in place. I then put the damper back to the 15° BTDC mark and reallign the rotor with #1 while also checking that the points have just started to open or the electronic pickup within the distributor is aligned with the stator depending upon which ignition system is being dealt with. The engine is then started and the timing fine tuned with a timing light. This only works where the damper ring has not slipped.