Ford Shop Tips – Volume 11 EAN: 978-1-60371-051-0 ISBN: 1-60371-051-5

Volume 11

September 1972 to August 1973

Technical parts and service information published by Ford Division to All 11 Issues assist servicemen in Service Stations, Independent Garages and Fleets. Great source of The complete collection of Shortcuts, Volume 11 "Shop Tips" Tips, How-To Articles and Tricks

Reference Guides

Specifications

Part Identification

TSB information

Each issue is jammed packed full of shortcuts, tips, and tricks to make repairs fast and easy.

Articles are written in plain, straight-to-the-point fashion and provide simple solutions to common problems Plus more Vol. 11 issues! Official Licensed Product of the Covers both Car Ford Motor Company and Truck models!

All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

Ford Shop Tips – Volume 11 EAN: 978-1-60371-051-0 ISBN: 1-60371-051-5

Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com

This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company.

Note from the Editor

This product was compiled from the original issues of the Ford Motor Company’s publication of the Ford “Shop Tips” magazine. Every effort has been made to use the original scanned images, however, due to the condition of the material; some pages have been modified to remove imperfections.

Disclaimer

Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.

A Mustang B Lincoln Continental

C * Continental Mark IV

D Montego E Ford

F Pinto G Comet

H 'Mercury

I Maverick

J * Cougar

K Torino L Thunderbird Technical parts and service information published by the Ford Parts Division and distributed by Ford and Lincoln-Mercury Dealers to assist servicemen in Service Stations, Independent Garages Here's What We and Fleets.

IN THIS ISSUE Have For You Page In this new Announcement Issue model announcement issue, you Here's What We Have For You IFC will find a host of timely and useful information. A Good Look At the Great Looking 1973's Information that will help you to discuss the new Ford Division Models 2-3 features of the 1 973 Ford of Fine Cars with Lincoln-Mercury Division Models 4-5 Family your customers and friends and enable you to New Technical Features For 1973 answer their questions. Impact-Absorbing Front and Rear And, a large section of Bumper Systems 6 this issue will also be helpful to you and your Exhaust Gas Recirculation men from a technical standpoint. (EGR) System ...... 7 For Wiper Arm Mounted Windshield example, we have included such advanced Washer Jets 7 details for each car line as: Lights and bulb wat Anti-Theft Alarm System 8 plus tage .. their trade number . Circuit Protec Spare Tire Lock ...... 8 tion rated . . 90 Ampere Alternator 9 including amperes and type . Approx Station Wagon Spare Tire Extractor ... 9 imate Refill Capacities of the various operating Emission Systems Required components plus Service Locations of the PCV

Maintenance Services ...... 10 valve, oil filler cap and hood latch release. Maintenance Schedules 11 If you are curious about the new Ford trucks, 1973 Specifications there are a number of pages devoted to these Ford V. . . .12-13 "workhorses" of the transportation industry. You Torino ...... , . , 14-15 Mustang 16-T7 will find similar specifications on all Ford trucks Maverick 18-19 from the F-100 on up to the larger 750 series

Pinto ...... 20-21 equipped with gasoline engines. Thunderbird . . , ...... 22-23 Of particular Bronco .24 importance is the story Ford Econoline ...... 25 has to tell this year of their engineering efforts Ford Trucks 26-29 directed toward increased passenger safety, Mercury ...... ,..,.^.,..30*31 Montego 32-33 vehicle sheet metal protection at low road speeds

Cougar ...... 34-35 and of course further improved and more sophis Comet ; 36-37 ticated control of exhaust emissions . .. espe Capri ...,..,...,...... 38*39 Lincoln Continental 40-41 cially the reduction in nitrogen oxides which is

Continental Mark IV 0...... 42-43 commonly referred to as NOx. Motorcraft and Autolite Part Numbers

Application Chart for 1973 Vehicles . .44-47

Be sure to file this and future issues for ready reference. If you Important Note: have any suggestions,for articles that you would like to see included in this publication, please write to: Ford Parts Division, Merchan Detailed information on the following new engi dising Services Dept, P.O. Box 3000, Livonia, Michigan 48151. neering features which apply to the majority of

The information in this publication was gathered from materials the 1973 Ford-built cars (either as standard or released the National Service Department of Ford Division by Parts optional) appears on pages 6 through 9. These and the Ford Customer Service Division of the Ford Marketing Corporation, as well as other vehicle and partsmanufacturers. The include: descriptions and specifications contained in this issue were in and Rear Bumper effect at the time it was approved for printing. Our policy is one of 1. Impact-Absorbing Front continuous improvement and we reserve the right to change spec Systems ifications or design without notice and without incurring obligation. 2. Exhaust Gas Recirculation (EGR) 3. Wiper Arm Mounted Windshield Washer Jets 4. Anti-Theft Alarm System Motorcraft^ 5. Spare Tire Lock

VOL. 73 MSD 1 LITH0 IN U.S.A.

m A GOOD LOOK AT THE

FORD DIVISION

NEW FEATURES FOR 1973

Impact-absorbing front and rear bumper systems. AM/FM/MPX stereo radio with Stereosonic tape Flame-retardant interior materials, system. Inside hood latch release. Fixed-length antenna. Spare tire lock. Improved rear window electric defroster. Improved AM/FM/MPX stereo radio. Improved cigarette lighter. Ww&ffimw. '

FULL-SIZE FORD windshield washer reservoir with a capacity of 2x/2 quarts (80 ounces), which replaces the 63 ounce reservoir Of all the Ford Division new cars, the full-size Ford is used in 1972. the most changed in outward appearance. There's new The hood release is now located inside the car for better sheet metal below the belt line ... a new front grille . . . protection against underhood theft. and a new greenhouse on all four-door models. Vinyl roof color selections are now expanded from five Sixteen models now comprise the four series avail to seven colors for 1973. Light Blue, Gold, Beige and able .. . Dark Green are new for this year while Black, White Interior convenience and luxury are improved by a and Dark Brown are carryover. completely new design of the instrument panel . . . new door trim panels . . . revised color trim selections and more front and rear headroom in the four-door models. MUSTANG All models in the full-size Ford lineup are equipped for 1973 has the convertible Select- Mustang only model in with the 351 CID 2V, V-8 engine coupled with the the Ford Division lineup of passenger cars. Five models Shift automatic transmission as the standard power team. are offered to the motoring public. Both the 400 2V and the 429 4V V-8 engines are con New grilles and color-keyed front bumpers of molded tinued as options. urethane (an impact resistant plastic material), are pri Ford-developed front disc brakes of the sliding caliper mary features of the new models. This new bumper con type are standard on all models for 1973. The single nects to the Ford-designed impact-absorbing devices in caliper piston is now 3.1 inch in diameter compared to the front body stub frame structure. the 2.75 inch piston size used previously. Parts com New optional Color-Glow colors are Blue Glow and 12 parts in plexity is greatly reduced since there are only Ivy Glow with new standard paint colors, Avocado and brake as compared to the 26 in the previous the new Tan. design. From a technical standpoint, all Mustangs for 1973 carry an improved brake system. Front drums on all hardtops and SportRoof models with the 250 CID IV TORINO six cylinder engine and the 302 2V, V-8 engine have and the Gran Torino have new front 10 x Both the Torino 2.5 inch brakes which replace the 10 x 2.25 inch size parking/turn signal lamps plus new of last year. grilles, new front In addition to this, the front suspension on extensions in the sheet metal. There is a all 1973 hood and fender Mustang models has been revised to provide an in these two recognizable difference between the grilles added Y inch in suspension travel. The power models. team combinations for 1973 Mustang are offered in four series .. . Gran models is the 250 IV six Eleven models Torino, cylinder engine as the base Torino Sport and Gran Torino Brougham. powerplant on all Torino, Gran models except the Mach I which low- low-back front bench seats with carries In the interior, the 302 CID 2V, V-8 engine as standard. restraints improve driver visibility. Options for the 1973 profile head Mustangs include: 14-inch forged options include a rear window electric defroster aluminum wheels, a leather New wrapped steering wheel and

. . treat . lower bodyside paint for the station wagons radial-ply steel-belted tires.

Sport series . . . ment for the Gran Torino radial-ply leather wrapped wheel. steel-belted tires and a steering MAVERICK High-back front bucket seats continue as optional Gran Torino and the Gran Torino Again in 1973, three models are equipment on the being offered. Or* the technical standpoint (and be base two- and four-door Sport models. From a models, a new grille is featured vehicle weight for 1973) larger rear that is similar to last year's cause of increased Grabber design on all models. There's a larger A new exterior color drum brakes are included Blue Glow is available GREAT LOOKING 1973'S

LTD BROUGHAM

In the interior new refinements include front seats of instrument panel. The fan motor is changed from a three-

new molded foam seat-back padding . . . thicker seat speed to a four-speed range to permit more exact circula cushion padding and softer seat springs. tion of air conditioned or heated air. Head restraints are the new low-profile design that A four-speed manual transmission is standard with blend into the seat top and curve over the seat back. the 1600cc engine on sedans and Runabout models while The steering wheel is the same as that used on the the 2000cc engine and four-speed manual transmission is larger Ford Division cars and features a two-spoke design standard on Station Wagon models. with a concealed horn switch in the outer part of the spokes. THUNDERBIRD Mavericks with the 200 CID six cylinder engine fea a new an . With front-end ture larger 10-inch front and rear drum brakes .. replac appearance, highlighted by "cross-hatch" ing the 9-inch size of last year. Ten-inch brakes remain extruded aluminum pattern grille, the 1973 on Mavericks with the 250 and the 302 powerplants. Thunderbird has a fresh new formal look. New, too, is a Five-bolt wheels are used this year compared to the classic stand-up hood ornament, oval shaped and carry four-bolt type used previously. ing the Thunderbird emblem. For safety, the ornament is Other technical features include impact-absorbing mounted with a spring-loaded fold-back device. front and rear bumper systems, a spare tire lock option New squared bright bezels surround the headlamps and an optional AM/FM/MPX stereo radio. while the combination park/turn/side marker lights on the leading edge of the fenders include new lenses with a design pattern that coordinates with the grille appear

PINTO ance. To further broaden the appeal of this little "carefree In the interior, a split bench front seat is standard

car" forged aluminum wheels will be offered for 1973. along with a left-hand remote controlled mirror, increased These styled wheels are 13 inches in diameter and five front and rear seat headroom plus an illuminated heater inches wide to provide added stability and improved fan switch. handling. Technical features new for 1973 include such engineer

Three models, the two-door sedan . . . the three-door ing items as: larger rear brakes; a 77 ampere-hour plastic Wagon in case side-terminal a 90 with Runabout .. . and the Station ( introduced late battery; amp alternator the flame-retar- 1972), are offered this year. However, several features optional rear window electric defroster; and and color combinations are new in this new 1973 lineup. dant interior materials. The new features include such standard details as a Thunderbird's standard engine is the 429 CID 4V passenger-side courtesy light, a fully enclosed glove box eight cylinder powerplant with SelectShift automatic lighter and illuminated identifi transmission while the 460 4V engine with lock ... a cigarette is optional. A spare

cation for the wiper/washer and heater controls. tire lock and inside hood latch release are new standard Also new for 1973 are A78 x 13 tires which are stan anti-theft features that make up just a few of the 1973 dard on the two-door sedan and three-door Runabout. refinements that are found in all 1973 Thunderbirds. These replace the 6.00 x 13 BSW of last year. From a Ride control is further improved by the addition of a technical standpoint, cooler running finned and flared Freon-filled plastic bag in the shock absorber reservoir two-door drums and wider linings are standard on the and an extra compression valve on the piston above the equipped with sedan and Runabout models. Pintos the rebound control valve. 1 rear axle 2000cc engine now offer as standard a 3.40 to Rear brakes are improved because of a l/i inch increase in brake width. ratio. lining Now, the effective lining area, Optional details include a spare tire lock, and air con which is directly related to overall brake performance, is center-placed registers in the increased 11 percent over ditioning with adjustable last year. A GOOD LOOK AT THE

LINCOLN-MERCURY DIVISION

NEW FEATURES FOR 1973 Anti-Theft Alarm System AM/FM/MPX radio with stereo tape system 77-Amp. side terminal batteryLincoln Continental Lincoln Continental, Mark IV and Mercury Marquis and Mark IV and Monterey Inside hood latch releaseLincoln Continental, Improved AM/FM/MPX radio full-size Mercury Mark IV, full-size Mercury and Montego and Comet Spare tire lockAll car lines

Fixed length radio antenna full-size Mercury, Improved rear window electric defrost option- Comet and Cougar Lincoln Continental, full-size Mercury and Cougar Right-hand remote controlled mirror Lincoln Coolant-recovery system added to Class III trailer Continental, Mark IV and full-size Mercury towingfull size Mercury and Montego

FULL-SIZE MERCURY all models, optional power steering with the power assist For 1973, the full-size Mercury, Marquis and Monterey mechanism enclosed in the steering gear housing, and a models have all new sheet metal below the belt line with larger windshield washer reservoir with an 80 ounce new greenhouses on all four-door models plus redesigned capacity which is 27 percent more than in 1972. and more luxurious interiors. The standard engine in all models except the GT and Radial-ply, steel belted tires are standard on all models. Station Wagon is the 250 CID, IV, six cylinder. The 302 Thinner windshield pillars set at a rakish 60 degree 2V V-8 is standard on the GT and Staion Wagons. angle help to impart a fresh new styling appearance. The standard transmission is the three-speed manual. In the interior, all door panels and seat trim are all- Options include radial-ply steel-belted tires and a rear new along with full-length armrests on all doors. Stow window electric defroster on station wagons. age area in the glove compartment ( 676 cubic inch capa city), is more than double that of 1972. Windshield washer jets are now mounted directly on the wiper arms for faster windshield cleaning, new door COUGAR "pocketless" weatherstripping ( type), reduces wind Cougar is the only model in the Lincoln-Mercury Divi noise by shaping itself to the glass contour and there's an sion lineup of 1973 cars that offers a convertible. It is interior hood latch release. available in both the Cougar and Cougar XR-7. Standard, too, are power operated front disc brakes (12 SelectShift automatic transmission and power front parts compared to 26 in the previous assembly ), of Ford- disc/rear drum brakes are standard equipment. developed design and an automatic parking brake release. The standard engine is the 351 CID 2V, V-8 with the Optional is a new theft deterrent, electronic alarm sys 351 CJ 4V, V-8 as an optional powerplant. tem that sounds the horn ( on and off for about 5 minutes ) The new grille is a one-piece die-casting with a bright if someone tries to gain forced entry into the vehicle. vertical bar design. At the top of the grille there's a new Also, Lincoln Continental type power operated vent Cougar or XR-7 emblem attached to the molding. Lenses front windows are available on all four-door models. for the turn signal/running lights are now clear plastic Flame retardant interior materials are standard with an amber light bulb. Two new vinyl roof colors are throughout the model lineup. available .. . Light Blue and Avocado. Standard on the Monterey series is the 351-2V, V-8 Radial-ply, steel-belted tires are available as an option powerplant with a SelectShift automatic transmission. in the GR78 x 14 size. On the Monterey Custom models, the standard engine is the 400 CID 2V, V-8, while the Marquis models have the larger, more powerful 429 CID 4V engine. MERCURY COMET

The 1973 Comet provides a higher level of com MERCURY MONTEGO luxury, fort and convenience in all three models. Front end styling is accented by an all-new center In the front, a slightly changed grille highlights styling grille, new fender extensions, new headlamp grilles and a while new side trim adds to the exterior design. There new contoured bumper. Model count remains at nine are new door trim panels, armrests with integral pull within the four series: Montego, Montego MX, Montego handles, bench seats with thicker seat cushion padding, MX Brougham and Montego GT. plus head restraints of a new low-profile design that blend New low-back front seats with individual right and left into the seat top and wrap-around on the back when they headrests are standard on all models. are pushed down. New technical features include larger rear brakes on Changes have been made in the suspension system that MERCURY MARQUIS MERCURY BROUGHAM MONTEGO BROUGHAM

COUGAR

are designed to provide a smooth ride and less transfer wall tires, and a wiper arm mounted windshield washer ence of sound into the passenger compartment. Rubber nozzle jet. Theft protection is increased by the placement insulators under the front springs eliminate metal-to- of the hood release inside the passenger compartment and metal contact and thus contribute to a quiet ride. a lock for the spare tire. Both are standard items on all All Comets with the 200 CID six cylinder engine will models. now be equipped with 10-inch brake drums both front New options for 1973 include a right-hand remote con four- and rear. Wheels used with the 10-inch brakes are also trol outside mirror and vent front windows on the new and feature a five-bolt attachment. door sedan.

Technical changes include a 77 ampere side terminal

battery . .. new front disc brakes . . . and of course the CAPRI impact-absorbing capability for front and rear bumpers are detailed in the following pages. Capri has a completely new instrument panel, a larger SelectShift automatic transmission coupled to the 460 standard engine and other significant refinements. New CID 4V engine continue as the standard power team. simulated body-side dual air scoops and a new tail lamp No optional engines or transmissions are available. assembly with integrated backup lamps plus five new Rear axle ratio is changed to 2.75 to 1 from the previous exterior colors make the Capri an award-winning design. 2.80 to 1 ratio. A 3.00 to 1 ratio continues as an option. Capri's sporty exterior also features a new blackout grille and new tail lamps. Interior changes include a lockable glove box and a new simulated walnut finish. Replacing the 1600cc engine CONTINENTAL MARK IV as the standard powerplant is the more powerful 2000cc For 1973, the classic Continental Mark IV presents a overhead cam, four-cylinder engine. A V-6 with 2600cc modified front end appearance with changes centered in (155 cubic inches), continues as an optional engine on the new front bumper with impact-absorbing capability the higher series Capri. and a revised version of radiator-shell four- the traditional The standard transmission on all models is the type grille. speed manual transmission with synchromesh in all Shock absorbers are mounted at a new angle and have forward gears. An optional automatic transmission is new engineering features to add to the ride comfort level. available on all models. The 2000cc engine is teamed with A Freon filled plastic bag placed in the fluid reservoir a 3.44:1 axle ratio while the 2600cc has a 3.22:1 gear set. fills the reservoir air space, thus reducing fluid aeration The Decor includes an electric rear window Group and under shock bucket- foaming high velocity absorber motion. defroster, unique front seats and separate contour Freon also helps in cooling the shock absorber fluid. style rear seats, an adjustable map light, simulated There is also an additional compression control valve. leather trimmed sports steering wheel, a fully reclining Mark IV rear drum brakes are increased from 11 x 2y4 front seat plus a simulated leather trimmed gearshift knob. inches to 11 x 2*/2 inches, providing approximately 11 percent more effective brake lining area. The 460 CID 4V, V-8 powerplant and the SelectShift LINCOLN CONTINENTAL automatic transmission continue as the standard power For 1973, a number of subtle refinements and changes team for 1973. The axle ratio is now 2.75 to 1 ( versus are introduced to maintain the Lincoln Continental as a 2.80 to 1 last year), with a 3.25 to 1 ratio as optional distinctive motor car. replacing the 3.00 to 1 ratio used in 1972. A Town Coupe which includes many exclusive fea Tire size is also increased from the 225-15 of last year tures found on the Town Car is added to the model lineup. to 230-15. Michelin white sidewalls that feature radial- Several noteworthy improvements include improved ply steel belted construction and the Sure-Track brake steel-belted side- sound insulation, larger radial-ply white system remain standard equipment. Motorcraft

HOW TO READ AND UNDERSTAND THE MFD. BY FORD MOTOR CO. IN U.S.A.

IDENTIFICATION PLATES ON FORD-BUILT CARS DATE: 09/72 GVWR 5892 GAWR: FRONT 2964 REAR 2928 AND TRUCKS FOR 1973 THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR AND PRIOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF YEARS MANUFACTURE SHOWN ABOVE

3S66H100001 PASSENGER

than). | axLi Technical parts and service information published by the Ford IMPORTANCE OF READING Parts Division and distributed by Ford and Lincoln-Mercury Dealers to assist servicemen in Service Stations, Independent Garages IDENTIFICATION LABELS OR PLATES

and Fleets. of a wide choice Over the past ten years Ford has offered a multitude models, power train options. it has been of optional equipment, and hundreds of And, a complete year and never said that Ford could run its production lines for (interior/exterior comfort and build the exact same model twice color, trim, convenience accessories, etc.). when you begin to into all IN THIS ISSUE This statement seems highly reasonable dig public. Your the possible combinations that are available to the motoring Page their per important role in servicing these models and maintaining safety, often depends to a large degree HOW TO READ AND UNDERSTAND THE formance, and emission control standards either the Vehicle Identification Plate IDENTIFICATION PLATES ON FORD-BUILT on your ability to "read and

Certification Label ... or the Truck Metal and CARS AND TRUCKS FOR 1973 ... the Safety Standard Rating AND PRIOR YEARS Warranty Plate. "interpret" system Ford uses in 1973 and prior Being able to the code IMPORTANCE OF READING confusion and prevent years will you to eliminate lost time, avoid ordering IDENTIFICATION LABELS OR PLATES 2 help incorrect parts or components. LOCATION OF CAR AND TRUCK This issue of Shop Tips is compiled to help you overcome those problems. IDENTIFICATION LABELS AND METAL PLATES 2 LOCATION OF CAR AND TRUCK 1973 FORD AND LINCOLN-MERCURY IDENTIFICATION LABELS SAFETY STANDARD CERTIFICATION LABEL INFORMATION 3 AND METAL PLATES 1970-72 FORD AND LINCOLN-MERCURY The Safety Standard Certification label for Ford-built passenger cars is located CERTIFICATION SAFETY STANDARD either on the Lock Face of the Lett Front Door or the Door Pillar. INFORMATION 4 Panel ol LABEL On Bronco units the Metal Rating Plate is mounted on the Inside 1963-69 FORD AND LINCOLN-MERCURY the Glove Box Door. Wagons have the Metal Plate riveted to the SAFETY STANDARD CERTIFICATION Econoline and Club Rating LABEL INFORMATION 5-8 Lett Front Door Lock Face Panel. The light, medium and larger trucks including school bus units, carry the 1966-73 BRONCO IDENTIFICATION Metal Rating Plate in various locations as described: INFORMATION 9 Stripped Parcel Delivery Units have the Metal Rating Plate in an Envelope Items" parts. 1971-73 CAPRI IDENTIFICATION and it is included in the "Boxed Plate Riveted to the Lett Front INFORMATION 10 Conventional Cab Units have the Metal Rating Door Lock Face Panel. ECONOLINE 1968-73 (E-100, E-200, Cowl and Windshield Units have the Metal Rating Plate Mounted to the Ver E-300 SERIES AND CLUB WAGON VAN) tical Surtace ol the Cowl Top Panel Under the Hood on the Passenger Side INFORMATION 10 IDENTIFICATION ol the Vehicle. affixed to 1963-67 FALCON CLUB WAGON NOTE: A Safety Standard Certification Label (Vinyl Coated) is also will found on the Door Latch & ECONOLINE each of the 1973 Trucks. This Decal be while W-WT Series IDENTIFICATION INFORMATION 11 Pillar for the F-C-CT-L-LN-LT-LTS-LNT Series the has this Decal on the Lett Side ot the Instrument Panel. 1966-73 TRUCK IDENTIFICATION INFORMATION-F-100 AND UP 12-13 HOW TO READ SPECIAL EQUIPMENT 1966-73 TRUCK ENGINE CODES (GASOLINE AND DIESEL) 14 (D.S.O.) CODES vehicles such as police taxis and special order trucks have cus 1966-73 TRUCK TRANSMISSION CODES .15 Many cars, tomer requested equipment installed at the factory, and are identified by a D.S.O. code (Domestic Special Order). D.S.O. codes have been stamped into truck plates since 1957 and pas senger cars since 1962. In addition, all vehicles delivered since January 1962 Be sure to file this and future issues for ready reference. If you with special equipment, have a blue envelope in the glove box containing a have any suggestions for articles that you would like to see included copy of the Special Equipment Parts List used on that particular vehicle. The in this publication, please write to: Ford Parts Division, Merchan selling dealer also has a yellow copy. P.O. Box Michigan 48151. number dising Services Dept. , 3000, Livonia, A typical D.S.O. number might be 13-0645. In breaking this down, the (13) indicates the District (in this example, New York) in which the vehicle was delivered. The indicates it was the 645th vehicle with spe The information in this publication was gathered from materials (0645) cial equipment delivered for that year. On some plates you may find a D.S.O. released by the National Service Department of Ford Parts Division number such as without a second series of numbers. This is NOT a and the Ford Customer Service Division of the Ford Marketing (13-) vehicle with special equipment. The number (13), for example, refers only to Corporation, as well as other vehicle and parts manufacturers. The the District (New in which the vehicle was delivered. descriptions and specifications contained in this issue were in York) To order special equipment parts for vehicles delivered after effect at the time it was approved for printing. Our policy is one of January use the D.S.O. parts list in the glove box. If this list is not avail continuous improvement and we reserve the right to change spec 1962, simply able then use the D.S.O. code on the Plate or the Certification Label. ifications or design without notice and without incurring obligation. Rating If neither is available, give your Ford or Lincoln-Mercury Parts Manager any information stamped or stenciled on the part you need. He, in turn, can then deliver the correct part you request. Heavy and Extra Heavy Duty trucks built at the Louisville assembly plant between August 14, 1967 and Mid-Year 1970 have a Truck Specification List (T.S.L.) in the glove box. From Mid-Year 1970 and for all 1971, 1972 and 1973 Motorcraft^ truck models you will find a plastic laminated T.S.L. located moisture-proof, as follows: All units except W, WT-9000, F-700, F-750, C and CT series with "B" sleeper compartment and series cowl units have the T.S.L. attached to the

Copyright 1972 right hand side of the upper inner back panel. side of Ford Parts Division The W, WT-9000 series have the T.S.L. attached to the right hand the Livonia, Michigan heater console. | The F-700, F-750 and C and CT series with sleeper compartment have the T.S.L. attached to the lower rear corner of the right hand door inner panel. "B" The series Cowl models have the T.S.L. placed in the glove com partment and the customer may attach it in any suitable position on the body VOL. 73 MSD 2 LITHO IN U.S.A. or chassis he chooses. 1973 FORD and LINCOLN-MERCURY SAFETY STANDARD CERTIFICATION LABEL

FORD TORINO PINTO MAVERICK . MUSTANG THUNDERBIRD

RANCHERO COUGAR MONTEGO COMET > MERCURY CONTINENTAL MARK IV . LINCOLN CONTINENTAL . (CAPRI NOT INCLUDED)

THIS DATE WILL CONFORM TO GVWR: GROSS VEHICLE WEIGHT RATING BUILD DATE OF VEHICLE

r ENGINE CODE GAWR: GROSS AXLE WEIGHT RATING (See Chart Below)

MFD. BY FORD MOTOR CO. IN U.S.A. VEHICLE CONSECUTIVE UNIT NO. IDENTIFICATION 1973 MODELS: (100,001 thru DATE: 09/72 GVWR 5892 NUMBER 499,999) for Ford, Torino, Mustang, GAWR: FRONT 2964 REAR 2928 Pinto. NOTE: Vehicle Identification Num Thunderbird, Maverick, (500,001 thru 799,999) for ber is also stamped on a metal fab THIS VEHICLE CONFORMS TO Mercury, Montego, Cougar, Comet. that is riveted to the instrument ALL APPLICABLE FEDERAL MOTOR (800,001 thru 999,999) for Lincoln panel close to the windshield on VEHICLE SAFETY Mark IV. the driver side of the car and is STANDARDS IN Continental, visible from the outside. EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE

"3" MODEL YEAR IS 1973 3S5 6H10000 11 PASSENGER ASSEMBLY PLANT i[} .

VtH. IDENT. NO. VEHICLE DATA MODEL CODE BODY | COLOR | TRIM TRANS. | AXLE | DSO 57F 1C DA W 6 48

BODY CODE (Use To Order Body Parts) DISTRICT or DISTRICT and SPECIAL ORDER (See Page 2 For Details) COLOR CODE (Use To Order REAR AXLE RATIO CODE (See Chart Below) Exterior Paint) TRANSMISSION CODE TRIM CODE (See Chart Below) (Use To Order Interior Trim)

REAR AXLE RATIO CODES

YEAR REGULAR RATIO LOCKING

1973 2 2.75:1 K 1973 ENGINE CODES 1973 3 2.79:1 L 1973 6 3.00:1 0 APPLICATION- CODE CYL. CID CARB. VENTURI 7* 1973 3.40:1 w 4 1600 cc IV P 1973 9 3.25:1 R 1973 A X 4 2000 cc 2V P 3.50:1 S G* 6 2600 cc 2V CA 1973 3.55:1

- v** T 6 200 2V MA, CO 1973 3.91:1 L 6 250 2V T-R, MA, MU PINTO ONLY -'MUSTANG ONLY MO, CO F 8 302 2V T-R, MA, MU MO, CO TRANSMISSION CODES H 8 351 2V F, T-R, MU, M YEAR CODE TRANSMISSION TYPE M0, CR MANUAL Q 8 351 4V(CJ) T-R, MU, MO, CR 1973 1 3-Speed S 8 400 2V F, T-R, M, MO 1973 E 4-Speed Pinto Only N 8 429 4V F, T-R, T, M, MO 1973 5 4-Speed AUTOMATIC A 8 460 4V F, T, M, L, MIV 1973 U C6 (XPL) C 8 460 4V Police F, T-R, M 1973 W C4 (XP) *F FORD, CA CAPRI, CO COMET. CR COUGAR, M MERCURY, MA MAVERICK, 1973 X Cruise-O-Matic (FMX) MO MONTEGO, MU MUSTANG. T THUNDERBIRD. T-R. TORINO-RANCHERO 1973 z C6 (XPL Special L LINCOLN CONTINENTAL. MIV MARK IV. P PINTO Police) JZ&&: 1970-72 FORD and LINCOLN-MERCURY SAFETY STANDARD CERTIFICATION LABEL

. . FORD . TORINO . PINTO . MAVERICK . MUSTANG THUNDERBIRD

. . MERCURY . CONTINENTAL . RANCHERO . COUGAR . MONTEGO COMET

. (CAPRI NOT MARK III, MARK IV . LINCOLN CONTINENTAL INCLUDED)

THIS DATE WILL CONFORM TO. ENGINE CODE MANUFACTURED BY BUILD DATE OF VEHICLE (See Chart Below) FORD MOTOR COMPANY NOTE: Vehicle Identification Num f CONSECUTIVE UNIT NO. ber is also stamped on a metal tab VEHICLE CONFORMS 1972 MODELS: (100,001 thru that is riveted to the instrument 08/71 T MS 499,999) for Ford, Torino, Mustang, panel close to the windshield on FEDERAL TO ALI APPLICABLE Thunderbird, Maverick, Pinto. the driver side of the car and is VEHICLE SAFETY STAN- (500,001 thru 799,999) for Mer visible from the outside. MOTOR cury, Montego, Cougar, OF Meteor, DARDS IN EFFECT ON DATE Comet. MODEL CODE, MAN [JRE SHOWN ABOVE. (800,001 thru 999,999) for Lincoln Mark IV. ASSEMBLY PLANT CODE. Continental,

BODY CODE MODEL YEAR CODE.

"0" (Use To Order is 1970 Body Parts) "1" is 1971 COLOR CODE "2" is 1972 (Use To Order Exterior Paint)

TRIM CODE NOTE: 1972 Exterior Color Codes are identified with two digits (Use To Order Inferior Trim) NOT TITLE OR REGISTRATION Example; 1C (Black) REAR AXLE RATIO CODE- MADE IN U.S.A. (See Chart Below) DISTRICT or DISTRICT AND SPECIAL ORDER CODE TRANSMISSION CODE (See Page 2 For Details) (See Chart Below)

ENGINE CODES TRANSMISSION CODES

YEAR CODE CYL. CID CARB. VENTURI CODE TRANSMISSION TYPE 70-72 A 8 460(a) 4V Manual 70-71 B 6 240(b) IV Police 70-72 1 3 Speed 70-71 C 8 429 4V Cobra Jet 70-71 5t 4 Speed Wide Ratio (2.78 1st Gear) 70-72 D 8 302(b) 2VTaxi 1972 5 4 Speed 70-72 E 6 240(b) IV Taxi 70-71 6 4 Speed Close Ratio (2.32 1st Gear) 70-72 F 8 302 2V 1972 E* 4 Speed 70-71 G 8 302(c) 4V Boss Semi Automatic 70-72 H 8 351 2V 1970 3-Speed Stick Shift 1970 J(f)/C(g) 8 429 4V Cobra Jet (CJ) Ram Air Automatic 1971 J 8 429 4V Cobra Jet (CJ) Ram Air 70-72 U C6 (XPL) 70-71 K 8 429 2V 1970 w C4(XP3) 70-72 L 6 250 IV 71-72 w C4(XP) 70-71 M 8 351 4V 70-72 X Cruise-O-Matic (FMX) 70-72 N 8 429 4V 70-72 z C6 (XPL Special Police)

1970 P 8 428 4V Police Interceptor tPINTO 3.65 1ST GEAR 'PINTO ONLY 71-72 P 8 429 4V Police Interceptor 1970 8 428 4V Cobra Jet Q REAR AXLE RATIO CODES 1971 Q 8 351(d) 4V-GT YEAR REGULAR RATIO LOCKING 1970 R(e)/Q(h) 8 428 4V Cobra Jet Ram Air 71-72 R 8 351(e) 4V Boss 70-72 2 2.75:1 K 71-72 S 8 400 2V 70-72 3 2.79:1 70-72 T 6 200 IV 70-72 4 2.80:1 M 70-72 U 6 170(j) IV 1970 5 2.83:1 70-72 V 6 240(b) IV 70-72 6 3.00:1 71-72 w 4 1600cc IV Pinto Only 70-71 B 3.07:1 71-72 X 4 2000cc 2V Pinto Only 1970 C 3.08:1 7* 70-71 Y 8 390 2V Regular Fuel 71-72 3.18:1 1970 z 8 429 4V Boss 1970 8 3.20:1 1971 NOTE 1 8 429 4VCJ Super 70-72 9 3.25:1 R 70-72 A 3.50:1 S 71-72 G* 3.55:1 71-72 H* 3.78:1 (a) 1970-72 Lincoln Continental, (e) Mustang 1970-71 Mark III, 1972 Mark IV (f) Fairlane, Ranchero 1970 3.91:1 V (b) Full Size Ford (g) Montego (c) 1971 Mustang; 1970 Mustang/ (h) Cougar 1970 4.30:1 w Cougar (j) 1971- 72 Maverick & Comet; 1971 3.91:1 V (d) 1971 Mustang, Cougar; 1972 Torino 1970 Maverick Ranchero, Mustang, Montego, Cougar 1971 4.11:1 Y NOTE 1: To determine identification of the Super Cobra Jet (Drag Pak) engine, 1972 3.91** V reference must be made to the Cobra Jet engine code PLUS Axle Ratio 3.91; 4.11 Code. PINTO ONLY MUSTANG ONLY 1969 FORD and LINCOLN-MERCURY

CAR IDENTIFICATION PLATES ^-tWkZEXX FORD FAIRLANE FALCON THUNDERBIRD MUSTANG RANCHERO COUGAR MONTEGO MERCURY CONTINENTAL MARK III LINCOLN CONTINENTAL

ASSEMBLY PLANT CODE " BODY SERIAL CODE

ENGINE CODE (See Chart Below) MODEL YEAR CODE-

CONSECUTIVE UNIT NUMBER

9S51V 100001 WARRANTY NUMBER &oTd NOT FOR TITLE OR REGISTRATION

BODY TYPE CODE (Use To Order Body Parts) TRANSMISSION CODE COLOR CODE (See Chart Below) (Use lo Order Exterior Paint) Non-acrylic Enamel Grey Plate Acrylic Enamel Black Plate Acrylic Enamel Gold Plate for Lincoln Continental only TRIM CODE DISTRICT or DISTRICT AND (Use To Order Interior Trim) SPECIAL EQUIPMENT CODE (See Page 2 For Details)

Ford Plate Shown. Other

plates same except for Mercury or Lincoln Continental logo.

ENGINE CODES TRANSMISSION CODES

CODE CYL CID CARB VENTURI CODE TRANSMISSION TYPE A 8 460f 4V Manual

240* 1 3 Speed B 6 IV Police 5 4 Speed Wide Ratio (2.78 1st Gear) D 8 302 2V Police &Taxi 6 4 Speed Close Ratio (2.32 1st Gear) E 6 240 IV Taxi Automatic F 8 302 2V U C6(XPL) H 8 351 2V W C4 (XP3) X Gruise-O-Matic (FMX) K 8 429 2V z C6 (XPL Special) L 6 250 IV

M 8 351 4V

N 8 429 4V REAR AXLE RATIO CODES

P 8 428 4V Police Interceptor REGULAR RATIO LOCKING Q 8 428 4V Cobra Jet F 2.35 1 (Mustang only) 2 2.75 1 K R 8 428 4V Cobra Jet Ram Air 3 2.79 1 S 8 390 4V Improved Performance 4 2.80 1 M T 6 200* IV 5 2.83 1 6 3.00 1 0 U 6 170* IV C 3.08 1 U V 6 240 IV 7 3.10 1 X 8 390f 2V Premium Fuel 8 3.20 1 (Falcon only) Q 9 3.25 1 R Y 8 390 2V Regular Fuel A 3.50 1 S fL-M only 3.91 1 V *Ford only 4.30 1 W Emergency Towing 1973 Ford-Built Passenger Cars

Hi TOWING .

TOWING A CAR PROPERLY IS SERIOUS BUSINESS

Not too many years ago towing a car was relatively a simple matter. Attaching the chain hooks to the Technical parts and service information published by the Ford front or rear axle or to bumper arms was all that was needed. Up went the car and away went the towing Parts Division and distributed by Ford and Lincoln-Mercury Dealers vehicle. Special precautions only applied to how fast or how far the manufacturer felt was safe for the car to assist servicemen in Service Stations, Independent Garages and and its dnveline components to be towed. Fleets. Not so for the past few years and especially not so for the 1973 models. Special precautions and special types of towing equipment are needed to bring in a disabled vehicle without damaging the body structure. First, you or your tow operator must make sure the disabled car has the parking brakes released and the transmission gears placed in neutral range.

IN THIS ISSUE

Page TOWING, JACKING, HOISTING TOWING A CAR PROPERLY IS SERIOUS BUSINESS 2

1973 . .3-8 TOWING THE FORD-BUILT CARS Figure1 Here is a typical and popular style wheeled dolly that can assist the tow FLOOR JACK PRECAUTIONS 8 operator in several ways. Its use avoids removing the driveshaft in bad weather and is extremely helpful when towing a car with no wheels, or complete wrecks. HOISTING INSTRUCTIONS-GENERAL. .9-11

OFF HIGHWAY PARTS CATALOG Equally important, the tow operator must know whether the transmission and rear axle are in proper INFORMATION AND OFFER 12 working order before towing from the front end. If the rear axle is damaged or has the rear wheels must be raised off the pavement NEW HEADLAMP BULBS FOR FORD- failed, and the car towed with BUILT CAR LINES 13 the front wheels on the roadway or supported on a wheeled dolly. See Figure 1. If the transmission is damaged or inoperative, the driveshaft must be removed prior to towing OR the rear wheels YEARLY INDEX FOR ALL 1972 SHOP TIPS raised ... on which is more convenient for the tow operator. To tow a vehicle with the ARTICLES 14 depending steering column and the transmission locked and no ignition key available, lift the vehicle from the rear. AUTO TECH AUTOMOTIVE HOME STUDY TRAINING COURSE OFFER 15 Note: If the car is equipped with an automatic transmission, with the selector lever in PARK position and no ignition key available, the rear wheels will be LOCKED. The car must then be towed with rear wheels raised.

If the wheels are locked in a turned position, the front wheels MUST BE SUPPORTED with a specifically designed wheeled dolly for towing. If the car is being towed with the rear wheels on the roadway, NEVER EXCEED 30 mph or a distance of 15 miles. If the tow operator finds that this is impossible, then it is advisable to tow the car with the rear wheels off the ground or with the driveshaft removed from the rear axle.

Be sure to file this and future issues for ready reference. If you have any suggestions for articles that you would like to see included TOWING SLINGS in this publication, please write to: Ford Parts Division, Merchan To avoid metal-to-metal contact and possible damage to chrome plated parts or lower panels, dising Services Dept., P.O. Box 3000, Livonia, Michigan 48151. body a special wide belt sling, shown in Figures 3 thru 24, should be used to lift and tow all 1973 Ford-built The information in this publication was gathered from materials passenger cars. As you will note in the following illustrations, some car models require ONE or MORE 4" 4" released the Service by National Departmentof Ford Parts Division x wood block spacers to insure that there is no lifting stress on the lower body panels. The suggested and the Ford Customer Service Division of the Ford Marketing lifting and towing hook-ups and the placement of spacers is illustrated in Figures 3 thru 24. Corporation, as well as other vehicle and parts manufacturers. The When towing Ford, Mercury or Meteor models from the front, first REMOVE the license plate and descriptions and specifications contained in this issue were in bracket to prevent the bracket and the bumper face. effect at the time it was approved for printing. Our policy is one of bending scratching On some Ford-built car a sheet metal spoiler removed when car either continuous improvement and we reserve the right to change spec lines, must be the is towed from the front or the rear end. ifications or design without notice and without incurring obligation.

I PROPER POSITION

I WRONG POSITION Motorcraft^

Copyright 1972 Ford Parts Division Livonia, Michigan 2 Figure From a safety standpoint and to protect your towing equipment, it is impor tant to have the wrecker boom in proper position when and vehicles. VOL. 73 MSO 4 LITHO IN U.S.A. lifting towing JACKING & HOISTING

TOWING THE 1973 FORD-BUILT CARS

Towing any one of the 1973 Ford-built models does not We urge you and your men to review these towing methods pose any serious problems even though they are equipped and make notes on any special equipment or materials needed in" with new impact-absorbing bumpers both front and rear. when you may be called upon to "bring a 1973 Ford-built However, as you will note in the following illustrations, passenger car. Doing this NOW will prevent any headaches each of the car lines has its own special method for safe for the tow operator and help him to become more of a towing and protection of the car body structure. professional in this field.

FORD-FRONT FORD-REAR

TOW-BAR TOW-BAR AUXILIARY HOOK AUXILIARY HOOK

4 Figure 3No wood block spacer is needed when towing from the Figure No wood block spacer is needed when towing from the "A" front. Auxiliary hooks connect to the suspension bottom rear. Auxiliary hooks attach to the axle housings inboard of the frames. springs.

THUNDERBIRD-FRONT THUNDERBIRD-REAR

TOWING SLING

TOW BAR

TOW-BAR

"ears" 6 Figure 5The retaining tabs are small located directly Figure No wood block spacer is needed when towing from the below the two front bumper face guards. The wood block spacer rear. Auxiliary hooks connect to shipping tie-down holes in the must be positioned forward of these tabs to prevent the spacer frame bottom section which are located about two feet to the from dislodging as the car is towed. Auxiliary hooks connect to rear of the axle. the stabilizer bar outboard of the rubber insulator blocks. TOWING

TOWING THE 1973 FORD-BUILT CARS

MUSTANG-FRONT MUSTANG-REAR

TOWING SLING TOWING SLING

TOW-BAR

4x4 BLOCK SPACER AUXILIARY HOOK

7 8 4" 4" Figure No wood block spacer is needed when towing from the Figure The four-foot, x wood block spacer should be "A" front. Auxiliary hooks are connected to the lower frames of placed across the rear section of the rear springs as shown. Aux the front suspension. iliary hooks connect to the axle housings between the springs and the wheels to prevent damage to the brake tubing and shock absorbers.

PINTO-FRONT PINTO-REAR

TOWING SLING

TOW-BAR TOW BAR

AUXILIARY HOOK AUXILIARY HOOK

4" 9 10 x4" Figure No wood block spacer is needed when towing from the Figure Place the four-foot, wood block spacer across front. Auxiliary hooks attach to the lower arms of the front sus the rear bumper face bar underneath the bumper guards as shown. pension, outboard but adjacent to the suspension struts. Auxiliary hooks must attach to the axle housings between the spring and the wheel to prevent damage to the brake tubing and shock absorbers. Without bumper guards, the wood block will nestle against the modesty panel and underside of the bumper.

IN THIS ISSUE

Page INFORMATION ABOUT CAR AND TRUCK ENGINE IDENTIFICATION GUIDE THE IDENTIFICATION PLATE PASSENGER CAR SPECIFICATIONS AMERICAN MOTORS 3

CHRYSLER CORPORATION (Chrysler, "decode" able read and vehicle identification plates Dodge, Imperial and Plymouth) .... 3-4 Being to plays an important role in the of cars and trucks. FORD MOTOR COMPANY (Ford, correctly servicing Lincoln and Mercury) 4-6 This is especially true during the last eight to ten model years

GENERAL MOTORS CORPORATION when several varieties of engines were developed for the motor (Buick, Cadillac, Chevrolet, ing public. Oldsmobile and Pontiac) 6-14

TRUCK SPECIFICATIONS From this wide variety of powerplant options, problems of correct CHEVROLET TRUCKS 14-15 engine identification have increased year by year. DODGE TRUCKS 15-16

FORD TRUCKS 16 Service technicians who only guess at the type of engine under the themselves not the speci GMC TRUCKS 17 hood, may find only applying wrong fications, but also ordering the wrong parts. INTERNATIONAL 18

JEEP 18 Therefore, correct engine identification by means of the identifi TECHNICAL SERVICE BRIEFS 19 cation plate plays as important a part in your service know-how

as do your service skills. You can find this vital engine informa tion in many ways. However, some methods take too much time or are just too difficult. CLARIFICATION The following is to clarify hoisting diagrams illustrated on For example, some car makers have the engine identification code pages 9 and 10 in the November/December, 1972 issue of this publication under the heading "Hoisting Instructions- number stamped on a flat machined surface of the engine block. General." This is not always easy to read since the code number often be The illustrations depicting frame contact hoist adaptor dimensions are not drawn to exact proportionate scale; comes obscured by grease, oil or road dirt or is only faintly visible thereto re the illustrations appear to conflict with dimensions because of poor at the factory. indicated for adaptor contact points C and D. stamping However, in every case, the dimensions specified in the captions for contact points C and D are accurate the code on of and should be adhered to in order to avoid damage to Too, stamping the block is often hidden in back the vehicle underbodies and components. air conditioning components or behind other optional accessories and their connecting hoses, pipes or lines making it difficult to read. Be sure to file this and future issues for ready reference. If you have any suggestions for articles that you would like to see included in this publication, please write to: Ford Parts Division, Merchan However, from 1968 up to the present model year (1973), all pas dising Services Dept., P.O. Box 3000. Livonia, Michigan 48151. senger cars have an identification plate riveted to the left front The information in this publication was gathered from materials corner of the instrument panel. This plate has a series of (both released by the National Service Department of Ford Parts Division digits and the Ford Customer Service Division of the Ford Marketing numerical and alphabetical), which can easily be observed from Corporation, as well as other vehicle and parts manufacturers. The of descriptions and specifications contained in this issue were in the outside the windshield. effect at the time it was approved for printing. Our policy is one of continuous improvement and we reserve the right to change spec ifications or design without notice and without incurring obligation. Therefore, ever since 1968, the task of correct engine identifica "decoding" tion is a breeze. All you need is the information taken

from the plate near the windshield.

This publication is designed to supply you with all the necessary "decoding" information for American-built passenger cars and

most light-to-medium-size trucks equipped with gasoline engines.

Keep this copy handy . . . near your work bench or tool chest. Copyright 1973 Ford Parts Division You'll find the information it contains will save you valuable time Livonia, Michigan and effort .. . and help keep you out of trouble.

VOL. 73 MSD 6 LITHO IN U.S.A. ENGINE IDENTIFICATION

To identify any engine by the manufacturer's code, follow the four steps designated by the numbered blocks.

D MODEL YEAR IDENTIFICATION: When shown as part of the Vehicle Identification Number, the year is indicated by the last digit of the model year.

0 ENGINE CODE LOCATION: Refer to illustrations of V.I.N, plates or engine blocks to determine location of engine code.

El ENGINE CODE : In the model year vertical column, find the engine code located in step 2.

Q ENGINE IDENTIFICATION: On the same horizontal line the engine code appears, read to the right to identify the engine. AMERICAN MOTORS

IDENTIFICATION MODEL YEAR AND ENGINE PLATE LOCATIONS: IDENTIFICATION:

MODEL YEAR ENGINE CODE 0 1964-67 (2nd (7th digit) digit) 6-cyl. Plate on NOTE: Digit refers to Both Alpha right wheel- betical and Numerical Characters. house panel under hood AMERICAN MOTORS I A3S050A100105 I 1964-67 V-8 1964-68 1968-73 D 1964,73 0 1968-73

0 ENGINE CODE ? ENGINE

HP.- 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 CYL. C.I.D. BBL. A A 6 L-hd. 196 1V 90 C C 60HV 196 IV 125 B. C 60HV 196 IV 127 B. CC 6 OHV 196 2V 138 JJ J A A A 60HV 199 1V 128 E E 6 OHV 232 IV 100 L L L L B B [ E 60HV 232 IV 145

' L L L L C C G 6 OHV 232 2V 155 A A 60HV 258 IV 110 A 6 OHV 258 1V 150 G G G V-8 287 2V 198 H H MM V-8 290 2V 200 N N N N V-8 290 4V 225 H H V-8 304 2V 150 H H V-8 304 2V 210 E E V-8 327 2V 250 F F F V-8 327 4V 270 S S S V-8 343 2V 235 z z z V-8 343 4V 280 N N V-8 360 2V 175 N N V-8 360 2V 245 P P V-8 360 4V 1951 P P V-8 360 4V 290 X X V-8 390 4V 315 X V-8 390 4V 325 Y V-8 390 4V 340 Z Z V-8 401 4V 255 Z V-8 401 4V 330

Net HP. shown-1 972-73. tDual Exhaust: 220-hp-.

H^^M^^^MMM^^Bi CHRYSLER CORPORATION Chrysler, Dodge, Imperial, Plymouth IDENTIFICATION PLATE LOCATIONS: M0DEL YEAR AND ENG|NE |DENT|F,CATION :

1964-65 1966-73

_ VEHICLE NO. ^ P452100105 "/- ) D MODEL YEAR 0 ENGINE CODE Q MODEL YEAR (3rd digit) (5th digit) (6th digit)

1964-67 1968-73 NOTE: Digit Refers to Both Alphabetical and Numerical Characters.

0 ENGINE CODE LOCATIONS:

1964-65 Engine code is a separate front of block, left bank, center, or number or precedes the engine se right bank. rial number and is located as fol n 6-cyl. lows: 6-cyl. Right side or top right 1966-73-V.I.N. Plate Number front of engine block. V-8Top

Copyright I973, Chek-Chorl, o Div of The H. M. Gouiho Co. Printed in U.S./ CHRYSLER corporatio IM Continued 0 ENGINE CODE ? ENGINE | HP." 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 CYL C.I.D. BBL. V-17 A-170 A 6 170 IV 101 A A A 6 170 1V 115 B 6 198 1V 94t B 6 198 1V 95 B 6 198 1V 100 B B 6 198 IV 125 C 6 225 1V 97t c 6 225 1V 105 c 6 225 1V 110 V-22 A-225 B B B B C C 6 225 1V 145 V-27 A-273 D D V-8 273 2V 180 D D V-8 273 2V 190 A-273 D E V-8 273 4V 235 G G V-8 318 2V 150 V-31 A-318 E F F F G G V-8 31 8 2V 230 H H V-8 340 4V 240 P P H H V-8 340 4V 275 J J V-8 340 3-2V 275 K K V-8 360 2V 170 K V-8 360 2V 175 K K V-8 360 2V 255 V-36 A-361 F V-8 361 2V 265 A-383 G G V-8 383 2V 270 L V-8 383 2V 275 A-383 G G G G L L V-8 383 2V 290 V-38 A-383 V-8 383 2V 305 N V-8 383 4V 300 A-383 V-8 383 4V 315 G H V-8 383 4V 325 V-38 A-383 H H L V-8 383 4V 330 H N V-8 383 4VH-P 335 M V-8 400 2V 1 81 1 M V-8 400 2V 185 M V-8 400 2V 1 90 M V-8 400 2V 275 P V-8 400 4V 246t P V-8 400 4V 255 P V-8 400 4V 260 V-41 A-413 V-8 413 4V 340 V-41 A-413 V-8 413 4V 360 A-426 V-8 426 4V 365 A-42. V-8 426 4V 415 V-42 H V-8 426 4V 425 JJJ R R V-8 426 2-4V 425 T V-8 440 4V 221 f T V-8 440 4V 230 T V-8 440 4V 275 T V-8 440 4V 335 J K K K T V-8 440 4V 350 U V-8 440 4VH-P 271 t U V-8 440 4V H-P 275 U V-8 440 4VH-P 280 J V-8 440 4VH-P 365 u V-8 440 4VH-P 370 L L L U V-8 440 4VH-P 375 V V-8 440 3-2V 330 V V-8 440 3-2V 385 V V V V-8 440 3-2V 390

H-P High- Performance. Net HP. shown for 1972-73. tCalifornia models. FORD MOTOR COMPANY

Ford, Lincoln, Mercury 1964-67 1968-73

Vehicle Certification Label appears IDENTIFICATION on lock face of left front door or PLATE LOCATIONS: door pillar. Alteration or removal will cause destruction of label or ap pearance of word VOID. D MODEL YEAR AND ENGINE IDENTIFICATION: / 1968-73 MAN FACTUREoA D 0 FOR MOTOR C'/^PANY 1970-73 D MODEL YEAR C /70 THIS /(HICll CON0OIMS Vehicle (1st T All Ap/lCAHJ F1DEAL digit) 0 )TO v/uCLI 1AFITY STAN- Certification 0 IDS lYlF!CT ON DATE OF

nu_/:tuf. SHOWN ABOVF. Label 0 ENGINE CODE _' (5th digit) c, SS.1F10OO0I '.O | A i-TTTw i NOTE: Digit Refers to Both Alpha C!_ *... 1.HIMIWO..TIU..O* betical and Numerical Characters. 1964-67 ,.,, J

LL ABOUT

INTRODUCTION

For the average motorist, batteries are unobtrusive black boxes under the hood. When called upon, they provide cranking fail and ignition voltage to get the engine going. When the Technical parts and service information published by the Ford they Parts Division and distributed and by Ford Lincoln-Mercury Dealers owner calls you! to assist servicemen in Service Stations, Independent Garages and Fleets. A recent AAA survey revealed that battery and related elec trical system failures accounted for nearly 45% of all road calls 33-million vehicles!

With today's trend toward options like big engines, air- conditioning, power seats, windows and antennas, stereo tape- ISSUE IN THIS decks, heated backlites and others, it's more important than ever BATTERIES before that batteries be properly maintained for owners to enjoy Introduction 2 all these extras! Battery Theory 3 All-new Battery Rating System 5 You can do your customers a favor Safety Precautions 6 big by including battery Reasons for Shortened Battery Life 6 service along with periodic services such as lubrication jobs, Maintenance 8 Battery Preventive tune-ups, etc. Battery Testing and Diagnosis 9 TECHNICAL SERVICE BRIEFS 15 Your customers don't want to wait until their battery fails, and then be forced to go wherever service might be available. They'd rather have you take care of it for them! They depend on you to help prevent premature failure. Don't let them down!

This issue is devoted to helping you know more about bat

customers' teriesand helping you to live up to your expecta tions! Be sure to file this and future issues for ready reference. If you haveany suggestions for articles thatyou would like to see included in this publication, please write to: Ford Parts Division, Merchan dising Services Dept., P.O. Box 3000, Livonia, Michigan 48151.

The information in this publication was gathered from materials released by the National Service Department of Ford Parts Division CAUTION: and the Ford Customer Service Division of the Ford Marketing Corporation, as well as other vehicle and parts manufacturers. The descriptions and specifications contained in this issue were in THERE ARE CERTAIN POTENTIAL HAZARDS CON effect at the time it was approved for printing. Our policy is one of continuous improvement and we reserve the right to change spec NECTED WITH BATTERY TESTING AND SERVICING. ifications or design without notice and without incurring obligation. THOROUGHLY REVIEW THE SECTION OF THIS

ISSUE TITLED "SAFETY PRECAUTIONS" AND PRAC

TICE THE STEPS OUTLINED WHENEVER YOU ARE

PERFORMING BATTERY WORK.

VOL. 73 MSD 8 LITHO IN U.S.A.

2 BATTERY THEORY

Figure 1

WHAT IS A BATTERY- AND WHY DOES IT WORK?

is Ever wonder exactly what a battery and why it works? One thing that a battery isn't is simply a storage tank for electricity!

The lead-acid storage battery that you're familiar with is an electro-chemical device for converting chemical energy into electrical energy. It stores electrical energy in chemical form! Current is produced by chemical reaction between the active materials of the PLATES and the sulfuric acid of the

ELECTROLYTE. However, current doesn't flow until any of the current-consuming devices on a car are connected across the battery terminalsor switched "on". You can create a simple storage battery by taking a lemon, cutting two slits in it as shown here, and placing a thin piece of lead in one slit, a thin piece of zinc in the other. If you touch your tongue across the two metal stripsyou'll feel a slight tingle. You have created electrical energy! Figure 2 The same principle is used in constructing a lead-acid than a simple cell. This is known as a compound battery ele storage battery. There are two unlike materialsa positive ment or cell. (Figure 5.) plate and a negative plate, kept apart by a porous separator. This is called an ELEMENT. (Figure 3.) - -2 VOLTS

POSITIVE NEGATIVE

NEGATIVE POSITIVE GROUP GROUP

Figure 5Compound battery element or cell. SEPARATOR When six compound cells are connected in series, you have

"battery" ELEMENT a of cells producing six times as much electrical energy as a simple cellor approximately 12 volts! (Figure 6.) Figure 3Simple battery element.

When this simple element is put in a container filled with

a mixture of sulphuric acid and water (called electrolyte), an approximate 2-volt cell is formed. (Figure 4.) Electricity will flow when the plates are connected to an electrical load.

CONTAINER ELECTROLYTE

Figure 6Typical 12-volt battery cell arrangement.

2 VOLT BATTERY CELL The most valuable characteristic of the lead-acid storage battery is its chemical reversibility. Whenever the chemicals of the battery have been "used

up" Figure 4Two-volt battery cell. by the discharge process, the potential energy may be restored by charging the battery. Charging takes place by By increasing the number of positive and negative plates passing an electrical current through the battery in the OP in an element you still have an approximate 2-volt cell, but POSITE direction of discharge! The battery's active materials with the capability of producing more total electrical energy are restored to a charged state. Servicing Ford's new

wmmi

: )t dj \ system... THE EGR SYSTEM

Technical parts and service information published by the Ford CONTROLLING EXHAUST EMISSIONS Parts Division and distributed by Ford and Lincoln-Mercury Dealers to assist servicemen in Service Stations, Independent Garages and Fleets. "NOx" You'll hear the term more and more as the auto industry continues its race against time to clean up the air in the U.S.A. What is NOx? Simply this: Oxides of nitrogen; a by-product IN THIS ISSUE resulting from the burning of fuel and air when the engine is run ning. It is invisible to the eye, practically odorless, and is caused Page by peak high combustion chamber temperatures that cause the THE EGR SYSTEM ... nitrogen and oxygen to unite. TESTING AND SERVICING

CONTROLLING EXHAUST EMISSIONS. 2 NOx STANDARDS The Federal Government NOx standard for grams. a of DESCRIPTION 3 all states for 1973 is 3.0 This is reduction, nationwide, more than 50% in only one model year when compared to the CONTROL OF EGR OPERATION 4 equivalent of more than a 4.0 gram limit required by California OPERATING DETAILS 5-6 in 1972. To meet this strict standard, Ford-built engines for 1973 have EGR VALVE OPERATIONS 6 added an EGR for most vehicle models . . . Exhaust Gas Recircula EGR OPERATIONS TESTING 7-8 tion system. By means of this new system, Ford is able to extract a 1 and direct it back to TESTING THE DUAL-AREA portion of exhaust gas (about 6 to 0 percent) chamber with the fuel/air DIAPHRAGM 8 the combustion by blending it incoming mixture. This 6 to 10 percent of exhaust gas, the by-product of MAINTENANCE SERVICE 9-10 down" combustion, serves to "cool peak combustion tempera HIGH-SPEED EGR MODULATOR tures of over 3,000 degrees F. SUB-SYSTEM 11-12 system on V-8s TESTING THE EGR MODULATOR FORD'S EGR SYSTEM Ford uses a built-in rather add-on pipes pick a portion of exhaust gas SUB-SYSTEM 12-13 than to up the and to meter it back into the fuel/air mixture entering the intake DIAGNOSIS CHART OF manifold. On V-8 engines, the only visible portion of the EGR sys EGR SYSTEM 14 tem is a thick spacer plate located between the carburetor base DIAGNOSIS CHART OF HIGH-SPEED and the intake manifold. A metering valve is also connected to one of EGR MODULATOR SUB-SYSTEM ... 15 end this plate. Both the 200 and 250 CID engines use an external stainless steel tube to direct hot exhaust gases to the EGR valve. It might be well to note here that controlling the formation of oxides of nitrogen presents different and at the same time, conflicting problems than that of limiting carbon monoxide and hydrocarbons. The lean combustion mixtures and high temperatures that are helpful in reducing both hydrocarbon and carbon monoxide have just the opposite effect on oxides of nitrogen. In fact, the formation Be sure to file this and future issues for ready reference. If you of oxides of nitrogen reach a maximum level at nearly the same have any suggestions for articles thatyou would like to see included air/fuel ratio that results in a minimum carbon monoxide and in this publication, please write to: Ford Parts Division, Merchan dising Services Dept., P.O. Box 3000, Livonia, Michigan 48151. hydrocarbon emission level! Also, peak concentrations of NOx increase with engine load as combustion temperature rises. The information in this publication was gathered from materials And, a richer fuel mixture of released by the National Service Department of Ford Parts Division reduces NOx but increases emissions and the Ford Customer Service Division of the Ford Marketing hydrocarbons. Too, leaner mixture and a retarded spark reduce as well as other vehicle and parts manufacturers. The Corporation, NOx somewhat, but cause driveability problems. descriptions and specifications contained in this issue were in to balance all of these factors and to achieve the effect at the time it was approved for printing. Our policy is one of Therefore, continuous improvement and we reserve the right to change spec degree of NOx control required, the basic EGR system was devel ifications or design without notice and without incurring obligation. oped. In fact, there are really TWO VERSIONS of the EGR sys tem. A more complicated system than the one we have briefly described is needed for some engine applications for the control of EGR and to provide acceptable engine operation at high speed cruise conditions. We will refer to this more sophisticated arrange ment later on as a HIGH SPEED EGR MODULATOR SUB-SYSTEM. MotorcraftE33 This issue of Shop Tips is designed to explain the mechanical details of both versions of the EGR system and to explain the operation, testing, and maintenance procedures. It may be well to remember too, that any malfunction or failure of this new system will Copyright 1973 EGR have a direct bearing on the starting Ford Parts Division and operating condition of the engine. As a result, it is strongly Livonia, Michigan System" urged that you use the chart "Diagnosis of EGR listed on

-pages 14 and 15 when necessary. VOL. 73 MSD 34 LITHO IN U.S.A. TESTING &

DESCRIPTION CARBURETOR VACUUM LINE

The EGR system (Exhaust Gas Recirculation) is an added emission control feature on all 1973 Ford-built cars, except the 1600 and 2000 cc engines. This system is also used on trucks rated at 6000 GVW or under (for all 50 states) when equipped with a 200, 240, 302, 360, or 390 CID engine. Also, for California only, the EGR system is used on trucks over 6000 GVW when equipped with a 360 or 390

cubic inch engine. Ford- As mentioned earlier, to reduce NOx levels of 1973 built engines, exhaust gases are metered through the EGR valve (see Figure 1), to a passage in the carburetor spacer in order to dilute the fuel/air mixture going to the combus tion chambers. This dilution of the fuel/air mixture lowers the temperature during combustion, thus limiting formation of nitrogen oxides (NOx).

On V-8 engines, the valve is attached at the rear of the carburetor spacer as shown in Figure 2. Exhaust gases are

then taken from a drilled passage in the exhaust passage

located in the exhaust crossover of the intake manifold. These

exhaust gases are then routed to a metered orifice through

the EGR valve to the passage in the carburetor spacer and fed into the primary bore(s). system the On 6-cylinder models, the EGR is basically INTAKE MANIFOLD same as that used on V-8 models, except that the exhaust gas ' EXHAUST GAS is taken from the exhaust manifold heat box on 240 directly CROSSOVER PASSAGE. CID engines or directly from the exhaust manifold and di rected through a stainless steel tube connected to the EGR

spacer on the 200 and 250 CID engines.

TYPICAL EGR SYSTEM: 351-C, 400 CID W/O AC

PVS VALVE TEMPERATURE CONTROLLED VACUUM VALVE EGR VALVE NORMALLY OPENED SOLENOID VALVE CHECK VALVE DISTRIBUTOR VACUUM ADVANCE SPARK DELAY VALVE THE EGR SYSTEM

chamber and into the flow of fuel/air mixture entering the CONTROL OF EGR OPERATION combustion chambers. Once the valve has been unseated, the only means of limiting exhaust gas flow is the size of the flow restrictor placed in the inlet port of the valve body. There are TWO factors that control the operation of the Restrictor size varies according to engine application. basic EGR system . .. ENGINE COOLANT TEMPERA Modulating-type valves have an additional disc added to the

TURE and CARBURETOR VACUUM. valve stem below the main valve as shown in Figure 4. This When engine coolant temperature is BELOW the specified modulating valve operates the same as the poppet type valve 60 95 125 level (either F., F., or F. depending on appli when vacuum is between approximately 3 inches of vacuum cation), the EGR system is locked-out by a temperature con and 10'/> inches of vacuum. trolled vacuum switch similar to the PVS switch used in 1972. When vacuum reaches approximately 1 0'/2 inches of vac This new vacuum switch, placed in series with the EGR uum, the lower disc (high vacuum flow restrictor) approaches

"TEE" vacuum line, is installed in a metal fitting at the front the shoulders of the valve seat and restricts the flow of ex of 6-cylinder models and in a metal connector of the heater haust gases. This modulation of gas flow is for the purpose hose on V-8 equipped models. See Figure 2. of improved driveability on certain engine models. The EGR This temperature valve receives vacuum from a port in the valve and the vacuum control valve CANNOT be disas carburetor body. This new port is similar to the spark port. sembled and must be replaced if damaged! When the valve is closed due to lower coolant temperature A Tapered-stem valve should never NO VACUUM is applied to the EGR valve and thus NO IMPORTANT NOTE: cleaned. plugged or the cause a rough idle condition EXHAUST GAS is fed to the air/fuel mixture. be If of to excessive it should be replaced. When engine coolant temperature reaches the specified due leakage, level (this will take approximately TWO minutes of engine the valve opens vacuum to be applied operation) allowing VACUUM OUTLET to the EGR valve. Exhaust gas is then fed to the air/fuel mixture. The second factor concerning EGR operation involves carburetor vacuum. Generally speaking, vacuum is fed to the EGR vacuum control valve when the primary throttle plate reaches a position corresponding to a road speed of approxi mately 20 mph under light acceleration. DIAPHRAGM NOTE: There are three types of EGR valves; the POPPET type and the MODULATING type. See figures 3 and 4. The TAPERED-STEM valve is not illustrated.

The Poppet type consists of a spring-loaded diaphragm plus a valve stem and valve that operates within an enclosed RESTRICTOR- valve body. See Figure 3.

vacuum the valve begins At approximately 3 inches of EXHAUST GAS to open. As the valve stem is pulled forward, it unseats the gases to flow into the chamber in valve and allows exhaust VALVE CLOSED VALVE OPENED e the valve. Intake manifold vacuum will then pull the gas from this

VACUUM OUTLET

VALVE STEM DIAPHRAGM LOW VACUUM VALVE

VALVE SEAT

HIGH VACUUM VALVE

RESTRICTOR

EXHAUST GAS

VALVE CLOSED (NO FLOW) VALVE IN MID POSITION VALVE IN HIGH POSITION (MAXIMUM FLOW) (RESTRICTED FLOW) o

SERVICING FORD'

INTRODUCTION

Technical parts and service information published by the Ford This issue of Tips contains three up-to-date feature Parts Division and distributed by Ford and Lincoln-Mercury Dealers Shop to assist servicemen in Service Stations, Independent Garages and articles on Ford-built car models. The first article concerns Fleets. the new Electric Choke you will find on Motorcraft 2V and 4V carburetors installed on Ford-built V-8 engines for 1973.

type" Although an "electric of choke was first used years IIM THIS ISSUE

ago . . . called the Sisson Automatic Choke . . . Ford engineers Page SERVICING FORD'S NEW have employed a unique method for using electric current to ELECTRIC CHOKE heat the bimetal choke spring. It is designed to reduce vehicle Introduction 2 emissions by more accurately matching choke operation Features 3 a wider range of conditions. able to under Operation 4 throughout Being Troubleshooting 5 stand the operation of this new electric choke and to be capa SERVICE TIPS ON 1973 WINDSHIELD ble of testing the unit properly is important to all service tech WIPERS nicians. Procedures for Wiper Arm Removal and Installation 6-7 Our second article covers service details on Windshield Wiper Arm and the 1973 Blade Adjustment 8 windshield wiper arms and blades used on Ford-built passen 1973 Wiper Arm and Blade ger cars. Simplified methods for and the Adjustment Chart 8 removing installing TECHNICAL SERVICE BRIEFS 9-11 blade and arm assemblies are discussed in detail. The infor AUTOMATIC TRANSMISSION mation is also important from a safety standpoint on 1973 INFORMATION models (except Mustang, Cougar, Comet, Maverick and General Background Details 12 Release" since a new "Slide latch How Automatic Transmission Fluid Pinto), device has been Levels Vary 14 incorporated to secure the arm to the wiper pivot shaft. De How To Check Fluid Level 15 forming or bending this latch to remove the arm assembly could lead to the arm and blade being thrown off the pivot shaft during wiper operation while the car is in motion.

Be sure to file this and future issues for ready reference. If you Article three is included in this issue of Shop Tips because have any suggestions for articles that you would like to see included in this publication, please write to: Ford Parts Division, Merchan the checking, adding, or refilling of fluid to Ford-built auto dising Services Dept, P.O. Box 3000, Livonia, Michigan 48151. matic transmissions is not as simple an operation as it ap The information in this publication was gathered from materials pears to be. It is not like adding oil to the engine crankcase. released by the National Service Department of Ford Parts Division and the Ford Customer Service Division of the Ford Marketing Corporation, as well as other vehicle and parts manufacturers. The Too many automatic transmissions are either seriously descriptions and specifications contained in this issue were in damaged or reach the transmission pre effect at the time it was approved for printing. Our policy is one of internally boneyard continuous improvement and we reserve the right to change spec maturely because a service technician added too much fluid ifications or design without notice and without incurring obligation. or failed to add a sufficient amount. Both are equally serious.

With that thought in mind, we urge you to carefully read the information outlined in the automatic transmission article. In doing so, you and your men will be completely up-to-date Motorcraft^ and fully aware of the recommended procedures set forth by Ford's automatic transmission service engineers.

VOL. 73 MSD 37 LITHO IN U.S.A.

HERE'S A COOL IDEA

Right in your neighborhood, there's a mighty large market ready to be tapped. Technical parts and service information published by the Ford Parts Division and distributed by Ford and Lincoln-Mercury Dealers It's a service market that is growing at a phenomenal rate. The to assist servicemen in Service Independent Garages and Stations, . Service! market? . . Automotive Air Conditioner Fleets. Since 1962, passenger cars coming off the assembly lines equipped with factory-installed air have gone from 12% of total production to almost 70% during the 1972 model year. Too, recreational vehicles and trucks are getting into the picture in ever-increasing numbers. Dealer-installed units and hang-on types of air conditioners swell this total still further. Estimates based on industry figures indicate that there are almost

40 million A/C units in operation today . . . about 4 out of every 10 cars on the road. By 1980 it is predicted this market will grow to 7 out of 10. IN THIS ISSUE As you can see, never before has there been such an increase in service sales potential on any automotive system. Equally important is Page the fact that air conditioners require maintenance and service on a AIR CONDITIONER SERVICE regular basis! MADE EASY Interesting, too, is the attitude owners have about their personal REVIEW OF AUTOMOTIVE REFRIGERATION CYCLE 3 car's air conditioner. Units that fail to deliver cool air because of a malfunction in the refrigerant system are never allowed to remain USING THE MANIFOLD GAUGE SET ... 4 usually in that condition. TESTING THE A/C SYSTEM 5-8 want their A/C system and seek REFRIGERANT SYSTEM ANALYSIS Owners operating they generally CHART 7 out a service outlet where they can get it fixed fast. SAFETY PRECAUTIONS 9 Are you in this picture? If not, you should seriously consider getting SERVICE PUBLICATIONS OFFER 10-15 prepared NOW so that you can actively and aggressively promote and perform air conditioner service. For starters, you'll need training, some special tools and inexpen sive pieces of equipment plus a small outlay for fast-moving parts, components, Refrigerant-12 and specially prepared and packaged com pressor oil.

EST. 80% EST. 72% | bS.3/o

Be sure to file this and future issues for ready reference. If you 44.4% have any suggestions for articles that you would like to see included in this publication, please write to: Ford Parts Division, Merchan 14.0% dising Services Dept., P.O. Box 3000, Livonia, Michigan 48151.

The information in this publication was gathered from materials 1963 1968 1972 1975 1980 released by the National Service Department of Ford Parts Division and the Ford Customer Service Division of the Ford Marketing PERCENT OF TOTAL INDUSTRY CAR PRODUCTION WITH FACTORY A/C Corporation, as well as other vehicle and parts manufacturers. The descriptions and specifications contained in this issue were in effect at the time it was approved for printing. Our policy is one of WHO HAS IT ALL? continuous improvement and we reserve the right to change spec or design without notice and without obligation. ifications incurring Motorcraft has all the necessary ingredients for making your approach to this huge market a reality. We have a full line of fast-moving, broad coverage parts, a complete training program available through Motorcraft's factory-trained instruc tors who are equipped with a mobile unit to bring training right to you and your men, and a wide assortment of quality tools and equipment Motorcraft3^ within the price range of most service outlets. Motorcraft merchandising traffic" aids and identification signs help you to "stop and bring them into your place of business. Copyright 1973 We urge you to read and study the information contained in this Ford Parts Division issue. Get a head start on what it takes to become an air conditioner Livonia, Michigan service technician. Prepare for your future. Remember, Motorcraft has all the details and everything you need VOL. 73 MSD 44 LITHO IN U.S.A. to take advantage of this growing service market. Let's become partners! FOR AIR CONDITIONER SYSTEMS

REVIEW OF AUTOMOTIVE REFRIGERATION CYCLE

In any Ford air conditioner system, liquid refrigerant (R-12) increased pressure in the condenser raises the R-12 conden

is stored in the receiver under high pressure. See Figure 1 . sation or saturation temperature to a point higher than that When the liquid R-12 is released into Lhe evaporator by the of the outside air. As the heat transfers from the hot vapor to expansion valve the resulting decrease in pressure and partial the cooler air, the R-12 condenses back to a liquid. The liquid boiling lowers its temperature to 21.7 degrees F., its new under high pressure now returns to the receiver where it is boiling point. As the R-12 flows through the evaporator coils, stored for reuse. The cycle is repeated over and over when passenger compartment air passes over the outside surface of ever the A/C controls are set for cooling. the coils. As it boils, the R-12 absorbs heat from the air and SPECIAL NOTE: The basic refrigeration cycle for the 6- thus cools the passenger compartment. In other words, heat cylinder compressor (used in Thunderbirds, Mark IV's and from the passenger compartment is absorbed by the boiling Lincoln-Continental models for is identical to that for refrigerant. The refrigeration cycle is now under way. 1973) the 2-cylinder compressor shown in Figure 1. The saturation temperature where NOTE: temperature (the It may seem difficult to understand how heat can be trans boiling or condensation occurs) of a liquid or vapor increases ferred from a comparatively cooler car passenger compart or decreases according to the pressure exerted on it. ment to the hot outside air. The answer lies in the difference

between the refrigerant pressure that exists in the evaporator To complete the cycle, the following remains to be done: and the pressure that exists in the condenser. In the evapora 1. Dispose of the heat in the vapor. tor, the expansion valve reduces the pressure and the boiling 2. Convert the vapor back to liquid for reuse. point below the temperature of the passenger compartment. 3. Return the liquid to the starting point in the refrigeration Thus, heat transfers from the passenger compartment to the cycle. boiling refrigerant. In the condenser, the compressor raises The compressor (Figure 1) performs these functions. It the condensation point above the temperature of the outside pumps the refrigerant vapor (containing the absorbed heat air. Thus, the heat transfers from the condensing refrigerant from the passenger compartment) out of the evaporator and to the outside air. The expansion valve and the compressor forces it under high pressure into the condenser which is simply create pressure conditions that permit the laws of located in the outside air stream at the front of the car. The nature to function.

EVAPORATOR

^*=M HIGH PRESSURE LIQUID

LOW PRESSURE LIQUID

HIGH PRESSURE GAS

LOW PRESSURE GAS

TO EXPANSION VALVE AND EVAPORATOR

changes" Figure 1Carefully note the "state of that occur as the Refrigerant-] 2 cycles through a typical A/C system. ON-THE-CAR SERVICE

To be able to properly test and diagnose air conditioning systems, a manifold gauge set must be installed so that it is connected into the closed refrigerant system. Two gauges are generally needed to properly read the HIGH (or dis charge) side of the system, while the other gauge is used to read the LOW (or suction) side of the system.

USING THE MANIFOLD GAUGE SET

NOTE: Before attaching the manifold gauge set or perform 2. Turn both manifold gauge valves fully clockwise to close ing any tests, make a complete visual inspection of the A/C the gauge set to the center outlet (service) hose. See Fig system. Look for such items as obstructed air passages in the ure 4. condenser; broken or loose drive belts; disconnected or 3. If the gauge hoses do not have the valve opening pins in broken wires; a loose clutch; broken, cracked or loose mount them, install special fitting adapters on the manifold gauge brackets. ing low and high pressure hoses.

Once you've made your inspection, attach a manifold 4. Connect the high and low pressure gauge hoses with gauge set to the system as follows: adapters, to the respective high and low pressure service valves at the compressor. See Figures 5 and 6. 1 . Remove the protector caps from the high and low pressure

service valves in the high and low pressure lines at the NOTE: If a charging station type of equipment is used, fol compressor. See Figures 2 and 3. low the manufacturer's instructions.

COMPRESSOR

2-CYLINDER TYPE TORINO AND SERVICE VALVE MONTEGO

SERVICE VALVE CLOSED SUCTION THROTTLING VALVE TO CONDENSER

*n* *""> Mi'lll ll"l

EVAPORATOR

VACUUM PUMP EXPANSION VALVE FROM RECEIVER/DEHYORATOR

2Protector caps cover Schrader- 6 Figure the Figure Here is a typical arrangement of service equipment for making A/C system type service valves found on A/C units that tests and to evacuate and charge the refrigerant system. have a suction throttling valve in the system.

COMPRESSOR

LOW HIGH 6-CYLINDER TYPE PRESSURE PRESSURE GAUGE GAUGE m kJ TO CONDENSER

K SERVICE VALVE

TO LOW PRESSURE TO HIGH SERVICE VALVE PRESSURE TO -- 1 L SERVICE VALVE R-12 W r SUPPLY TANK \to VACUUMN"; JU\; / ; , \\ ' r DllkJQ SERVICE VALVE

3 4 5 Figure Protector caps cover the gauge Figure A manifold gauge set is a vital Figure Service connections for an A/C sys- hook-up fittings at the compressor service piece of service equipment for servicing A/C tern equipped with a 6-cylinder compressor valves on A/C units with a thermostatic units of all types. switch in the system.

TRAILER TOWING

YOUR ROLE IN SERVING THE RECREATION VEHICLE MARKET

Technical parts and service information published by the Ford Parts Division and distributed by Ford and Lincoln-Mercury Dealers to assist servicemen in Service Stations, Independent Garages and Fleets. Millions of Recreational Vehicles are out on the roads and highways of this country. And, aggressive owners or managers of service stations as well as independent garages can realize a healthy profit from promoting the services needed by such a great and growing market. IN THIS ISSUE This RV (Recreational Vehicle) market includes travel trailers, camp ing trailers, tent trailers plus smaller-size trailers used to transport boats, Page snowmobiles and motorbikes. Part of your promotion must center around your ability to give knowl TRAILER TOWING . .. TIPS AND FACTS and to an owner of an RV unit. In YOUR ROLE IN SERVING THE edgeable answers valid suggestions other speak with and thus create confidence. RECREATION VEHICLE MARKET . . 2 words, authority Being THE BIG FOUR IN TRAILER TOWING. 3 capable of doing this will help to prevent a driver having road break SERVICE MAINTENANCE TIPS downs, equipment failures and even accidents. Equally important is the FOR THE TOWING VEHICLE 4-5 fact that many owners unknowingly follow improper towing procedures, LUBRICANT SPECIFICATIONS 5 use inadequate equipment, or overload their RV unit. ENGINE LUBRICATION RACK Your counselling with such RV owners may prevent the vehicle's SERVICE POINTS 6 warranty being voided in case of mechanical failures and increase their CHASSIS LUBRICATON RACK loyalty to your service outlet. Remember too, poor RV preparation or an SERVICE POINTS 7 under-capacity towing vehicle often ends up with an owner who is stuck SAFE TOWING MUST START with a repair bill and/or ruined vacation plans. WITH PROPER EQUIPMENT 8 hefty Your job? get with of HOW TO FIGURE THE CAR AND First, fully acquainted all the available informa TRAILER CAPABILITIES 9 tion about the RV industry. Get to know the problem areas connected THINGS TO KNOW AND UNDER with towing RV trailers of all types and weight classifications. Get to STAND ABOUT HITCHES 10 know the capabilities and factory recommendations of their vehicles RECOMMENDATIONS- TOWING when used to tow RV units. Get involved with the needs and maintenance FORD DIVISION MODELS 11-12 services required by owners of these RV units. TOWING RECOMMENDATIONS- Look into the many opportunities you have to extra income into LINCOLN-MERCURY bring

your place of . . . .'. . business service . . . DIVISION MODELS 12-13 accessories vacation/camping items. TECHNICAL SERVICE BRIEFS 14-15 Look to the increased exposure and extra profits that can result from

serving such a huge market ... the fastest growing market in the recreational/travel industry! Begin now by reading this issue of Shop Tips. In the following pages you will find many helpful service tips, factory recommendations for 1973 Ford-built passenger cars, and information helpful to you in maintaining Be sure to file this and future issues for reference. If you ready RV units and towing vehicles. have any suggestions for articles that you would like to see included in this publication, please write to: Ford Parts Division, Merchan dising Services Dept., P.O. Box 3000, Livonia, Michigan 48151.

The information in this publication was gathered from materials released by the National Service Department of Ford Parts Division and the Ford Customer Service Division of the Ford Marketing Corporation, as well as other vehicle and parts manufacturers. The descriptions and specifications contained in this issue were in effect at the time it was approved for printing. Our policy is one of continuous improvement and we reserve the right to change spec ifications or design without notice and without incurring obligation.

Motorcraft^

U.S.A. IN . . VOL. 73MSD46 LITHO A big market . right in your own backyard! TIPS AND FACTS

THE BIG FOUR IN TRAILER TOWING

Four things are necessary to make trailer towing safe, 4. Selection of the proper hitch. pleasurable, and free from road breakdowns for you or for your customers. Avoiding or overlooking any one of these four items can cause trouble. They are:

1 . Proper lubricants and maintenance for the towing vehicle and the trailer.

In Item I, it is generally agreed that towing a trailer in classification II or III puts the towing vehicle in the SEVERE SERVICE category. Thus, normal maintenance schedules are shortened, not only to protect the owner's warranty but also to prevent mechanical failures.

marriage" And, as pointed out in Items 2 and 3, a "good of the trailer and the towing vehicle (or the towing vehicle and the trailer) is extremely important. Briefly, it would be

marriage" considered a "bad if a trailer in the Class II or III category is towed by a towing vehicle capable of properly 2. Selection of a vehicle that will handle the towing properly handling only a Class I trailer. For example, a 1 973 Maverick, trailer classification desired. Mustang or Pinto is NOT RECOMMENDED for towing anything but a Class I trailer with a maximum frontal area of 25 square feet. Attempting to pull a Class II or III trailer can only lead to mechanical failures, road breakdowns and unsafe towing.

Item 4, Selection of the Proper Hitch, is also a critical factor in safe trailer towing. Generally, there are two major types of trailer hitches: The WEIGHT CARRYING-SIMPLE BALL

type which is considered as non-equalizing . . . and the WEIGHT DISTRIBUTING type which is considered load

equalizing.

As you will also note in the chart, a trailer in the Class I category requires only a simple weight carrying hitch while those in Class II and III require a load equalizing hitch. To determine what type of hitch is needed, review the columns 3. Selection of a trailer that can be towed safely. for Gross Trailer Weight and for Tongue Load.

TRAILER CLASSIFICATION CHART

TRAILER (LIGHT) (MEDIUM) (HEAVY) CLASS 1 M III GROSS TRAILER 2000 lbs. WEIGHT UP TO... 3500 lbs. 6000 lbs. L* TONGUE LOAD UP TO... 200 lbs. 500 lbs. 700 lbs.

WEIGHT WEIGHT TRAILER HITCH WEIGHT CARRYING DISTRIBUTING TYPE DISTRIBUTING (Simple Ball) (Load Equalizer) iLoad Equalizer) TRAILER TOWING

SERVICE MAINTENANCE TIPS FOR THE TOWING VEHICLE

NO UNHAPPY TRAILERING Fluid levels can be considered an important part of towing a trailer safely. And often, a fluid level check will point out Proper maintenance of and system. For ex the towing vehicle the trailer serious trouble developing in the particular is a must if the vacation-bound traveller is to have a safe, ample, if you find the hydraulic brake fluid extremely low in trouble-free trailer towing trip. the master cylinder reservoir, this is generally a clue to a leaky Some of the more aggressive service stations and indepen wheel cylinder or to leaks elsewhere in the hydraulic system. dent garages "clue" advertise their capability to inspect, check and This same applies to finding an extremely low fluid service trailer gear and also feature pre-vacation fluid to towing safety level in any one of the other systems that require and maintenance for the towing vehicle. operate.

HERE IS A LIST OF THE SAFETY AND CONDITION CHECKS FOR THE TOWING VEHICLE THAT SHOULD BE PERFORMED TO INSURE NO UNHAPPY TRAILERING

COOLING SYSTEM Hoses Radiator All Drive Belts Coolant

All hoses for the engine cooling system and for the heater REAR OF ENGINE should be visually inspected for signs of weakness in the hose walls caused by deterioration of the inner wall surfaces.

AUTOMATIC TRANSMISSION DIPSTICK

ELECTRICAL All Lights Headlight Alignment Turn Signals/Emergency Flasher System Horn Wiper/Blades/Washer

In this area of maintenance and inspection, proper func tioning of the electrical circuits and electrical devices is vital from a safety standpoint, especially so for the owner towing FLUID LEVELS a trailer. It is suggested that headlight alignment should be Transmission made only when the trailer tongue load is known. With this Axle information, an equivalent weight can be placed in the towing Master Cylinder vehicle rear luggage compartment (also add sufficient weight Windshield Washer Reservoir to approximate the extra gear and/or luggage that will be Battery carried in the trunk. Headlights then can be aligned with Radiator greater precision to match actual trailer towing conditions Power Steering Reservoir on the open road. Servicing th Distributor. Technical parts and service information published by the Ford Parts Division and distributed by Ford and Lincoln-Mercury Dealers to assist servicemen in Service Stations, Independent Garages and Fleets.

INTRODUCTION

Servicing a distributor is a whole lot more than just installing a new set of contact points. Often the cause of breaker points becoming severely pitted, turning blue from heat or failing com IN THIS ISSUE pletely, can be traced to other sources and not the points Page themselves. SERVICING DISTRIBUTORS Today, with both the pivoted and the pivotless type of points INTRODUCTION 2 assembled as a set onto an attaching base, installation is gen THE HEART OF THE IGNITION SYSTEM 3 quite simple. And, although there are different methods TROUBLE ISOLATION 4-6 erally COIL TEST SPECIFICATIONS 6 for adjusting distributor point gap, if you've installed one set of DESCRIPTION OF DISTRIBUTORS 7-11 points you are capable of installing and adjusting almost every BREAKER POINT ADJUSTMENT 11 type found on American made passenger car and light truck BREAKER POINT TENSION SPRING engines. ADJUSTMENT 12 IGNITION TIMING 12 With that in mind, this issue of Shop Tips is devoted to the

CHART ON ENGINE TIMING AND complete servicing of the distributor assembly ... all the way CYLINDER FIRING ORDER 13 from checking, testing, and/or replacement of the condenser, CHARTS ON DISTRIBUTOR GENERAL INFORMATION 14 the rotor, the cap, the distributor cam, and both the centrifugal TECHNICAL SERVICE BRIEFS 15 and vacuum advance/ retard mechanisms. Complete servicing of the distributor is also vital in controlling and maintaining the engine's exhaust emission level so that it adheres to strict Federal Emission Standards. Too, distributor point gap, ignition timing, retard and Be sure to file this and future issues for ready reference. If you dwell, haveany suggestions forarticlesthatyou would liketoseeincluded advance of the spark so as to meet varying road speed and load in this publication, please write to: Ford Parts Division, Merchan conditions, is critical in today's engines. when the dising Services Dept, P.O. Box 3000, Livonia, Michigan 48151. And, servicing distributor, you should also be constantly on the alert to the fact The information in this publication was gathered from materials that point released by the National Service Department of Ford Parts Division life is directly affected by charging system voltage, and the Ford Customer Service Division of the Ford Marketing battery condition, electrical connections anywhere in the pri Corporation, as well as other vehicle and parts manufacturers. The descriptions and specifications contained in this issue were in mary circuit, point alignment, point gap, condenser capacity ... effect at the time it was approved for printing. Our policy is one of lubrication of the cam, condition of the upper distributor shaft continuous improvement and we reserve the right to change spec ifications or design without notice and without incurring obligation. bushing and various other rotating/moving distributor me chanisms.

On the following pages, you will find some simple methods for checking the electrical side of the distributor using accurate

testing equipment .. . charts covering up-to-date specifications . . . service details on distributor adjustments and ignition timing MotorcraftESS procedures and features of the Motorcraft distributors used in 1 973 Ford Division and Lincoln-Mercury Division passenger cars. Because Motorcraft distributors are engineered andi Copyright 1973 highly Ford Parts Division precisely calibrated mechanical devices using quality parts, this Livonia, Michigan assembly deserves quality attention by professional service VOL. 73 MSD 48 LITHO IN U.S.A. technicians. THE DISTRIBUTOR

THE HEART OF THE IGNITION SYSTEM

At a road speed of 60 mph, a set of distributor points in Continuing, let's also say that in this brief span (at 1000 an 8 cylinder car opens and closes about 200 times a second! revolutions per minute) a piston travels 20 degrees. Therefore in And, only one hour of operation at that speed, point open a spark must start at 4 degrees BEFORE top dead center ONE- and . ing closing occurs at astronomical figures . . over (BTDC) (Figure 11, to have the full force of combustion at HALF MILLION TIMES! 16 degrees AFTER top dead center (ATDC). On of each time top that, they open, they stop the flow of Now, to carry this further ... if you double the engine 25 watts of electrical energy. approximately Adding it up, in speed to 2000 rpm . . . then the distance the piston travels just 10,000 miles of operation, this energy would amount to is also doubled to 40 degrees. Because of this rpm increase over ONE BILLION WATTS. the spark must then start at 24 degrees BEFORE top dead Within the distributor housing there are other units that center in order to obtain the full force of combustion at 16 also take a severe beating and yet must perform precisely and degrees AFTER top dead center. Most centrifugal advance continuously in order for the engine to run properly. mechanisms continue to advance the spark until it reaches For example: the innocent looking condenser. Without it, approximately 30-35 degrees before top dead center ... an the (high secondary tension) voltage could not build up advance that varies among the vehicle manufacturers and enough to jump the gap at the spark plug, and the points different engines. would burn up in just a few minutes. In other words, the centrifugal advance mechanism is In at mph "time" fact, 60 road speed, the condenser must function needed to keep the spark in with engine speed; over 200 times in ONE SECOND to discharge the ignition coil a wide range of engine rpm. Size of the centrifugal weights

after each spark. and tension of the return springs are two of the major con Underneath the points and condenser is a centrifugal spark trolling factors in accomplishing correct distributor per advance mechanism. This mechanical device is necessary in formance. order to advance the spark correctly. For example: Let's Distributors generally also have one other advance mech assume that the engine piston must be at 16 degrees PAST anism in addition to the centrifugal weights ... a vacuum top dead center (ATDC) to get the full force from combus advance unit. This vacuum advance device provides additional tion. This 16 degrees (ATDC) must stay the same regardless advance over and above that which the centrifugal advance of engine speed. See Figures 1 and 2. mechanism is capable of providing. However, the engine does Now, let's also assume that it takes 2/1000 of a second not benefit from this vacuum advance during full throttle

for the combustion to exert full force on the piston head. operation . . . only during a part throttle position.

4 DEGREES BTDC

16 DEGREES 16 DEGREES

24 DEGREES BTDC

Figure 1An example that at 1000 rpm a spark Figure 2An showing occurring example showing that at 2000 rpm, a spark occurring at BTDC will cause combustion to exert maximum force at 24 4 degrees degrees BTDC will cause combustion to exert a maximum on the head of the piston at 16 degrees A TDC. force on the head of the piston at 16 degrees A TDC. SERVICING

TROUBLE ISOLATION

TESTING ELECTRICAL SIDE OF THE DISTRIBUTOR

Whenever it is necessary to pinpoint a problem in the ignition system, there is one quick test that you can perform to determine whether or not the malfunction is in the SEC ONDARY (high tension) circuit or in the PRIMARY (battery current) circuit.

NOTE: Excessive voltage drop in the PRIMARY circuit reduces the secondary output of the ignition coil and results in hard starting and poor engine performance. A breakdown in the PRIMARY circuit can be caused by one or more of the following: defective primary wiring; loose or corroded terminals; burned, badly pitted, shorted, sticking or improperly adjusted distributor points; or an open or shorted coil or condenser. A breakdown in the SECONDARY circuit can often be traced to fouled or IMPROPERLY GAPPED spark plugs; defective high tension wiring or high tension leakage across the coil, the distributor cap, or the rotor resulting from hairline cracks (often invisible to the eye); or to an accumulation of dirt on ignition system parts

or assemblies. Figure 3A strong secondary (high tension) spark should jump the when the condenser distributor and To check the spark intensity at the spark plugs, thereby gap regularly coil, rotor, cap, high tension wires to all spark plugs, are in good condition. isolating the ignition problem, proceed as follows: Disconnect a spark plug wire. BATTERY-TO-COIL VOLTMETER TEST

Check the spark at one wire at a time intensity plug by The first thing to do is to connect the voltmeter leads as a terminal adapter inserting in the terminal of the wire to shown in Figure 4. be checked. Then, connect a jumper wire to the distributor terminal 3/16" Hold the adapter approximately from the exhaust of the coil and to a good ground connection on the distributor manifold and crank the engine using an auxiliary starter housing. switch. The spark should jump the gap regularly. See Figure 3. Turn the ignition switch ON and make sure all lights and accessories are turned OFF. If the spark intensity of all the wires is satisfactory, then the coil, the condenser, the rotor, the distributor cap and the secondary (high tension) wires are probably in satisfactory condition.

However, if the spark is good at only some of the wires, VOLTMETER then check the resistance of those particular wires. If the spark is equal at all wires but weak or intermittent, check the coil, distributor cap, the coil-to-distributor high tension wire and the primary circuit.

The wire should be clean and bright on both conducting PRIMARY WIRE ends and in the wire sockets of the coil tower and distributor. FROM SWITCH TO

"B" The wire should also fit snugly . .. snap into place. TERMINAL

NOTE: Some distributor cap inserts are made of a metal that is not compatible with the spark plug wire. A sure way to avoid deterioration of the cap sockets is to use a distributor cap that has terminals which are highly conductive and able to resist corrosion and carbon buildup. Motorcraft caps and rotors meet these requirements and are precisely balanced in perfectly matched sets.

PRIMARY CIRCUIT TESTS

In order to isolate these problems in the primary circuit, you will need an accurate voltmeter. A good voltmeter is needed to perform the following checks: to Coil Test Ignition Circuit Test Battery Starting 4 Figure Here, the voltmeter is connected into the ignition electri Resistance Wire Test Coil to Ground Test Breaker Points cal system in order to make a test of the battery-to-coil circuit and Test the starting ignition circuit test.

SAFETY WORKING

Technical parts and service information published by the Ford Parts "DUMB" Division and distributed by Ford and Lincoln-Mercury Dealers to MOST ACCIDENTS ARE . . . assist servicemen in Service Stations, Independent Garages and Fleets.

IN THIS ISSUE

Page accidents are foolish and the ... if they're not dumb, majority SAFETY WORKING AROUND CARS can be avoided. MOST ACCIDENTS ARE "DUMB" 2 WE ALL NEED REMINDERS 2 But, to avoid becoming an accident victim, foresight is needed.

KEEPING YOUR SERVICE SHOP SAFE .. 3 Advance thinking might be a better way to put it; thinking ahead PERSONAL SAFETY 4 in order to prevent broken bones, busted heads, punctured skin, LIVING WITH PRESSURIZED CANS 5 or permanent disability. GASOLINE CAN BE DANGEROUS 5 pierced eyes, severed fingers SAFETY USING POWER TOOLS, There's no question about the fact that working around service POWER EQUIPMENT 5-6 EYE AND FACE PROTECTION 7 shops, four-wheel vehicles, engines and shop equipment is WORKING SAFELY WITH COMPRESSED much more dangerous than working in a flower shop or rolling AIR 7 bandages. SAFETY STANDARDS MOST FREQUENTLY VIOLATED 7-8 Service technicians use power equipment of all kinds; elec FIRE PREVENTION SAFETY 8 trically operated tools, compressed air, flammable liquids and SAFE PRACTICES IN THE EVENT OF A FIRE 9 hydraulically operated jacks and hoists in their day-to-day work. GIVE YOUR SERVICE SHOP THIS And there are literally hundreds of other hazards. All can be QUIZ ON SAFETY 10-14 potentially dangerous to your life and your livelihood if not treated HOW TO BECOME CERTIFIED BY THE NATIONAL INSTITUTE FOR AUTO with respect. MOTIVE SERVICE EXCELLENCE 15 Even though no one deliberately works in an unsafe manner, hundreds upon hundreds of men SPECIAL NOTE who earn their living in the automotive and truck service industry get hurt each year. Some OSHA . . . OCCUPATIONAL SAFETY AND HEALTH ACT who are luckier lose only their income for a few days or weeks With the passage ol the Occupational Safety and Health

. . . Act in 1970, many employers and their employees have some end up in hospitals ... a number end up with their own become more conscious of unsafe work habits and unsafe farm" "small at the local cemetery. Let's all continue work conditions. working "smart" OSHA, to put it briefly, is a compilation of the vast . . . starting today. majority of safe work standards and a clear definition of these standards; all intended for employee protection throughout the United States. Small employers, those with less than eight employees. are exempt from the OSHA recordkeeping requirements. However, all employers, including small employers, must continue to meet the requirements to report fatalities or WE ALL NEED REMINDERS multiple (five or more) hospitalizations. The intent of this publication is to point out as of In this issue of many Shop Tips, we will discuss the majority of potential the OSHA safe work practices and safe working conditions hazards that can lead to an as possible in one issue. Although we have not been able accident when working around cars. to cover the entire range of OSHA standards as set forth All the way from using screwdrivers with bad tips to more serious in the Federal Register, we sincerely hope that both em hazards such as a ployees and their employers take the time to go through raising car with a leaking hydraulic jack or this publication, study it and then correct any bad safety hoist. situations that may not have been recognized earlier. we Now, can't give you a breakdown of the number of acci dents that occur Be sure to tile this and future issues for ready reference. If you have only in the automotive and truck service industry any suggestions for articles that you would like to see included in each year (service independent service this publication, please write to: Ford Parts Division, Merchandising departments, garages, fleet Services Dept., P.O. Box 3000, Livonia, Michigan 48151. stations, shops), yet a bona fide report states that "Each year U.S. workers The information in this publication was gathered from materials suffer thousands of injuries on-the-job and released by the National Service Department of Ford and the Cus an number are . alarming disabled . . about 90,000 of them per tomer Service Divisions of the Ford Marketing Corporation, as well disabled." as other vehicle and parts manufacturers. The descriptions and manently And, "each year, 1 14,000 die from illnesses specifications contained in this issue were in effect at the time it and accidents suffered on-the-job . . . TWICE the number who was approved for printing. Our policy is one of continuous improve die in auto accidents." ment and we reserve the right to change specifications or design without notice and without incurring obligation. In fact, as one leading magazine article stated, "The work place be twice as may dangerous as even the nation's streets and whose highways, carnage is lamented public MotorcraftE32 officials." constantly by

Need we more Copyright 1973 say about keeping yourself alert to possible Ford Parts Division accidents your Livonia, Michigan during daily work hours? We think not! VOL. 73 MSD 50 LITH0 IN U.S.A. AROUND CARS

or on a slick concrete floor is a potential time KEEPING YOUR Grease oil bomb. The rule should be .. . clean it up promptly. Even if SERVICE SHOP SAFE the grease or oil spot does not cause a worker to slip, the

accumulation gets on shoes ... is tracked into other work areas and often ends up as tracks on the customer's floor mats. If you are concerned about your own safety and that of A customer's wrath can be fatal ... that is ... he becomes a your then it stands to reason that proper main co-workers, show" dough" "no meaning "no when he needs automotive tenance of the work area is a must. When we talk about area service again. maintenance, we include getting rid of oil or grease spots on oil . the . of metal such as cover the floors . picking up pieces discarded Using inexpensive oil-absorbent material to

now," mufflers, rusted out tailpipes, old used engine blocks, dam or grease spots or spills "right is a safe and sound aged and failed parts of a vehicle (old fenders, grilles, hoods, method for treating this potential accident-causing hazard. bearings, shafts, castings, etc..) and placing them out into a Supplies of absorbent material should be kept in a con

. well-travelled trash collection area . . away from the work venient location and all service personnel should be advised areas. to use it immediately when needed.

Other potential hazards to service personnel are open drain covers or broken, missing or lost underfloor exhaust eliminat ing outlets covers.

Projections or openings of drains that can catch a foot, or covers that do not fit snug or flush to the floor surfaces often is the cause of many needless trippings, resulting in broken bones or serious physical injury.

Leaving a creeper in an aisle-way or out in the open work area is another unsafe shopkeeping habit. Failure to park your creeper is an invitation for someone to trip over it, or step on it and fall. That someone might be you or one of your valued workers or a customer visiting your shop. Either of

these situations can result in a pack of headaches ... not to mention the increased insurance rates and necessary paper work that follows such accidental injuries.

Workbenches should also be kept neat and orderly. Tools and parts should be kept away from the bench edges so they cannot be knocked off. And generally, the old "Selective Gravity"

principle prevails in such incidents. That is . ..

"whenever a part or tool that weighs more than 3 pounds falls

"bones" Figure 1 When the discarded from old cars litter the from a height of over 216. feet it will always land directly on it." work area not look to customers, floor, they only unsightly they the foot of the person nearest to That not only hurts ... it are potential causes of accidents. Keeping the service shop free of can break a toe or small bone in the foot. A cast is-a heck of old parts by discarding them into a junk collection area as soon as a price to for such an prevented accident. possible is good common sense. pay easily

Figure 2Grease and oil on the service shop floor is an accident 3 about to happen. Each man in the service shop should be respon Figure If your workbench looks like this, take a few minutes bomb" sible for cleaning up such a potential "time as soon as it to straighten it out. Heavy parts that are knocked off always follow Gravity" occurs. the "Selective principle. Keep it clean and stay safe. SAFETY WORKING

Safely storing oily rags, waste materials and other such flammable items in containers designed specifically for such a PERSONAL SAFETY purpose is a must in order to reduce the danger of fires.

These containers should have metal tops that close tightly. If your service shop does not have this type of receptacle, No one wants to work in an unsafe manner and no one bring this to the attention of your boss or manager. believes or thinks he is working in an unsafe manner. Yet, there are countless numbers of accidents that point to just Does your service shop do gas welding of any kind? If so, such actions on the part of a service technician. To counter the compressed oxygen and acetylene cylinder tanks must be act such acts and to remind ourselves that some of the work stored with protective caps over the valving. And, equally habits we have been accustomed to over the years can lead to important, these compressed gas cylinder tanks must be serious injuries, let's review some that are most prominent. securely chained or strapped in an upright position so that there is no chance for them to become knocked over or tipped. A compressed gas cylinder with the valve knocked off is a lethal weapon. The high pressure gas escaping from a WORK CLOTHES rupture can cause the tank to shoot off in all directions at

tremendous speeds. Be safe ... keep them securely confined! The proper fit of work clothes and maintaining them in a Another mustwhen operation is being per any welding clean condition is essential. Sleeves or cuffs that are torn or formed, make sure there's a serviceable water handpump hang too loosely can be extremely dangerous, especially when handy and a good fire extinguisher. working around rotating parts of an engine or near service equipment such as brake drum lathes, wheel balancers, dyna mometers, etc. Equally important is keeping any outer gar ment buttoned and a loose hanging tie tucked into a shirt. Wearing a bow tie is another way to keep accident-free.

If a rotating pulley, gear or drive belt should catch a loose or hanging piece of clothing or tie, there is usually no time for you to pull away and free the entangled item of clothing. Hands and fingers can get pulled into the rotating machinery within a split second resulting in a serious injury.

Removing rings, watches or identification chains with metal bands is another safety measure to be remembered when working around vehicles. This is especially true when testing or servicing electrical components. Many severe burns and permanent scars have resulted from such oversight.

Moral: Metal objects are perfect conductors for bridging and short-circuiting electrical current. For your safety, make sure you wear no metal jewelry when working around engines.

Figure 4Compressed gas cylinder tanks must always be securely strapped or chained in an upright position. Never allow them to stand free or be stored without protective caps in place.

Another of the cardinal rules for welders is this: Never

attempt to make repair welds to a wheel with the tire inflated!

Heat will cause a huge increase in air pressure inside the

tire and this excessive air pressure has been known to cause

the tire to explode ... maiming and sometimes killing the welder.

Lubricating fluids needed to help install the tubeless tire may turn to a dangerous vapor when exposed to the welding torch heat level. When mixed with air, the combination can "bomb." make this a

.. use Follow the safety rule . "never weld or a cutting torch to trim metal or parts from a wheel with the tire still installed!"

wheel before Figure 5-A Always remove a tire from a doing any professional service technician is also a professional in his apparel. Loose brazing, welding or cutting. Never just deflate the tire and let hanging ties, torn sleeves and hanging pieces of are clothing extremely dangerous when around engines remain on the wheel. It would still be possible to create an working it and shop equipment. Customers have more confidence in service explosive mixture inside the tire. personnel who keep themselves neat.