The National Parts Return Program

DOT HS- 805 146

TL 242 /

. N384 v . 3 THE NATIONAL PARTS RETURN PROGRAM

Volume III: PRP News and Program Inputs

M. Lowery P. Karawanny

B. Miller R. Recard

Kappa Systems , Inc. 1501 Wilson Blvd. Arlington, Virginia 22209

Contract No. DOT HS- 6-01433 Contract Amt. $90,970

July 1979 FINAL REPORT

This document is available to the U.S. public through the National Technical Information Service, Springfield, Virginia 22161

Prepared For

U.S. DEPARTMENT OF TRANSPORTATION

National Highway Traffic Safety Administration

Washington, D.C. 20590 This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Government assumes no lia- bility for its contents or use thereof. Technical Report Documentation Pape

1 1. Report N«. 2. Government Accession No. 3. Recipient's Catalog No.

DOT_HS_805 L46

4. Till* Submit 5. Report Oat* 1 July 1979 » NATIONAL PARTS RETURN PROGRAM . 6. Performing Organization Coda FINAL REPORT VOLUME 3 PRP NEWS AND PROGRAM- INPUTS 3. Performing Organization Report No.

7. Author*) KAPPA-DOT- 79-01 M. Lowery, P. Karawanny, B. Miller, R. Recard

9. Perform* ng Organization Noma and Address 10. Work Un.f No. (TRA1$)

Systems, Inc. 1 1 Kappa . Contract or Grant No. 1501 Wilson Blvd. HS-6-01433 Arlington, Virginia 22209 13. Typ# of Rpport and Period Covored

12. Sponsoring Agency N on,* ond Address Final Report Department of Transportation 1 Julyl978 to 30 June 1-979 National Highway Traffic Safety Administration 14. Soensonng Agency Cod* Office of Defects Investigation N41-60

15. Supplementary Not**

16. Abstract

The National Parts Return Program involves the voluntary submittal by independent automotive repair facilities of failed automotive components and information. The purpose of the program is to gather information on these components and failure reports to assist the NHTSA in identifying the existence of safety-related manufacturing defects in design, materials, construction or performance of motor vehicles and motor vehicle equipment. Under authority of the National Traffic and Motor Vehicle Safety Act of 1966, as amended, the NHTSA can require manufacturers to conduct safety defect recall remedy campaigns when it has been determined that a defect relating to

motor vehicle safety exists. In addition, the information obtained fronfTflBHU parts and i reports is valuable in preparing Federal Motor Vehicle Safety Standards. DEPARTMENT ME TRANSPORTATION

DEC 2 8 19/9 !

library -

\ !

17. Key Word* 18. Distribution Sfofomenr

Parts Return Program Document is available to the public through Defects Investigation the National Technical Information Service, Springfield. Virginia 22161

9 19. Security Clossif. (of this report) 20. Security Clossif. (of this page) 21. No. a) age* 22. ?r ic« unclassified unclassified 266 1

Form DOT F 1700.7 (S-72) Reproduction of fo rm and completed page is authorized i FACTORS

CONVERSION

METRIC

11 Acknowledgments

This work was performed under contract number DOT HS-6-01433.

KSI's Contract Technical Manager was Mr. Gary Woodford, Engineering Analysis

Division, Office of Defects Investigation, National Highway Traffic Safety

Administration, whose assistance is gratefully acknowledged. KSI would also like to recognize the support for this project provided by Mr. William Risteen,

Acting Chief, Engineering Analysis Division, Office of Defects Investigation,

NHTSA. Lastly, we wish to express our appreciation to Ms. Joanna Schneider for her patient secretarial support.

111 ' ' ' " ' ' •; i . . .

’ ' ‘ ' : ’ ‘•v :

. :

' /

TABLE OF CONTENTS

Volume 3

Section 1: Newsletter Matrix 1

Section 2: PRP News, Volume 4 16

Section 3: Monthly Summary of Parts Received 52

SECTION

AVAILABLE

COPY

BEST I

jl 1 t SUSPENSION

UZ 3 a e'- er.

oo a

5; z TIKES

WHEELS,

I IT.

C: o C c

a at-

3 Aimcr.FR

1979

June

NKWRUcTTrcn 1978

•Tilly

pur

4 Aimoi.RR

1979

Juno

Nn:wR!,!!T.rnn 1978

July

pup

5 K t;

1979

June

1978

July

o / SYSTEMS

FUEL

CC t: B C: cr < o c

GO t- c; LC

7 (Cont.

SYSTEMS

FUEL

V. t: Q — O'. r-— at>

< 70) Z. c

' c— •— «r. LC i-H £ >. z •=?

8 AIITICLES 1979

June

NEWSI.ETTEH 1978

July

HP I’

Q SYSTEM

ELECTRICAL

C-.

cr.

c; c

C: >

10 1979

Juno

1978

July

00 \ 00 \c- 1 <30 fH 11 ANTICLES

1979

June

LETTISH -

1978

NEWS July

I'HP

12 13 1070

.hinr;

1078

.Inly

14 I

I p* o

jx: I ^ t-4 o O c o CC s».Q c ES C CO c ,p“- a o o — CO Q o CO c 0) c J- £ o cO £ cc w c J- !J CO A0CFSS0K1 *c o o 13

15 A Q*J*AySa

parts return 5/4tes O' program (news u S DEPARTMENT OE TRANSPORTATION e NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4 No. 1 July 1978

CARBURETOR FLOAT SATURATION REPORTS two 1973 Dodge Darts, seven 1974 Valiants and two 1974 Darts. The Champion Parts Rebuilders, Inc. of of significant, safety- related conse- average mileage on the 1973 ve- Oakbrook, Illinois, recently submitted quences. The agency is still in- hicles was 44,000, ranging from to the PRP detailed information on terested in problems associated with 16,493 to 73,010. The average carburetor float saturation in a va- later model vehicles, however, espe- mileage on the 1974 vehicles was riety of models. According to Cham- cially any float saturation situation 29,000, ranging from 23,780 to pion, which services over one million which may have caused engine com- 39,253. carburetors per year, problems have partment fires. been encountered with nitrophyll car- Contributing brake hoses in the past buretor floats. The floats are made year were WISCONSIN DOT, Madison, Wise.; of a closed cell, plastic composition PLYMOUTH/DODGE BRAKE KOLESNIK's SERV- ICE, material but begin to absorb gas- HOSE CRACKS Rochester, New York; DAY-NITE oline after a few years of service, AUTO, Kaukauna, Wisconsin; AUTO according to Champion. This can BRAKE CORPORATION, Norfolk, Vir- ginia; cause carburetor flooding and thus WOODY’s GARAGE, Mon- creates a potential for engine com- toursville, Pennsylvania; A. RUTH’s partment fires. GARAGE, Colonie, New York; MR. BRAKE #9, Pocatello, Idaho, and Champion reports that among BUD JONES SERVICE, Delmar, New 1974 and 1975 carburetors being York. We’d like to thank these shops serviced, saturated floats run as high as well as others who have contrib- as 80%. Carburetors affected include a wide variety of models man- uted suspect brake hoseS during the ufactured by Holley, Carter, Autolite past three years. Additional infor- and Rochester. mation on this potential problem The PRP has recently received ad- would be appreciated. ditional saturated floats from BOB CHESTER’S AUTO SERVICE, Arlington, Texas; AUTOMOTIVE CITY SERVICE CENTER, San Francisco, California; SPECIAL CONTRIBUTORS and AUTO BRAKE CORPORATION, As we begin a new PRP year Norfolk, Virginia. Two floats were (July, 1978—June 1978), we’d like removed from 1974 Mustang ll's, Based upon a large number of to take time out to thank two while a third float was removed from parts received from PRP members, special shops which have con- a 1974 Pinto. Approximately 21 the NHTSA has recently opened an tributed parts and information to carburetor float saturation problems enigneering analysis into brake hoses the program for twelve consecutive have been reported by program on Chrysler Corporation vehciles. months: AUTO BRAKE CORPORA- members over the past three years. The analysis involves brake hoses TION, Norfolk, Virginia and HARRY’s AUTO SERVICE, The NHTSA recently closed an from 1973 and 1974 Plymouth Val- Great Barrington, Massachusetts. Our investigation into carburetor float iants and Dodge Darts. The hoses' sincerest thanks to George Casper saturation in Rochester QuadraJet allegedly develop cracks and splits of Auto Brake and Harry Billings carburetors installed in 1965— 1972 near the fitting. of Harry's, as well as their staffs, General Motors vehciles. The case During the past year, PRP shops for their continuing contributions (C—44) was closed with no finding of have contributed brake hose from 17 to automotive safety. a defect, primarily because of a lack vehicles: six 1973 Plymouth Valiants,

16 CLUTCH CABLE PROBLEMS ON MUSTANG’S

Last year, BOB's AUTOMOTIVE, Dayton, Ohio, submitted information to the PRP on the possibility of a construction defect in the clutch cable connection on a 1974 Mustang

II with 37, 714 miles. Allegedly, the connector for the cluth pedal ripped away from the firewall of the vehicle, causing a premature en- gagement of the clutch. The driver experienced a loss of control but was able to avoid an accident. Since that time the NHTSA has received five Hotline calis from individuals who have experienced the same problem. Each case has involved breakage at the firewall on

1974 Mustang ll's. Reportedly, as the clutch pate wears, the increased pressure on the cable connection at

the firewall is too great for the thin gauge firewall metal, and can cause the metal to tear, creating a potentially dangerous situation.

A similar condition on Ford Pintos was mentioned by BOB’s AUTOMO-

TIVE in a recent telephone contact.

NHTSA OPENS THREE NEW INVESTIGATIONS The Pinto clutch cable is held in

NHTSA recently opened three new vehicles without power steering. The place by ‘‘spring ears” which re- investigations involving Ford Motor problem involves the steering cou- portedly provide the same kind of

Company vehicles and Fiat vehicles. pling flange which is part of the support as they do for a parking The investigations involve fuel leak- steering mechanism. Allegedly, a brake cable attached to the backing age problems, steering mechanism pinch bolt used on this flange can plate on drum brake-equipped ve- problems and front wheel bearing loosen, resulting in a number of prob- hicles. The thin gauge metal in the failures. lems which can permit the steering firewall, however, can give way. Fuel line leakage in 1975 and wheel to rotate freely without turning Let us know of any similar situa- 1976 Ford Granadas and Mercury the wheels of the vehicle. In Jan- tions you've seen involving clutch Monarchs is ‘being investigated by uary of 1978, Ford initiated a recall the agency. The investigation was of 1974 Pinto and Mustang II ve- cable connectors. initiated on the basis of eight com- hicles for the same problem. plaints of fires in Granadas and The third investigation involves Monarchs equipped with V8 engines. front wheel bearings on 1973— 1977 OOOPs!! Last months News Information from the manufacturer Fiat 128 and X— 1/9 vehciles which contained a slight defect. The indicates at least 75 complaints of can result in loss of vehicle control cover photo was printed up- fires on the V8 model. There are due to wheel looseness, lockup or side down .... Sorry! approximately 568,000 vehciles in- separation. Twelve complaints of volved. Fuel leakage allegedly oc- such failures have been received by TELEPHONE CALLS curs at the point where a small NHTSA, and information obtained rubber hose connects the metal fuel from the manufacturer indicated over If the part you'd like to return is line to the fuel filter which is at- 900 complaints. too large or you simply haven't the tached to the carburetor. Any information on these cases time today to send in an information The steering case involves 1973— from our members would be ap- form, why not give us a (COLLECT

1975 Pinto, II Mustang and Bobcat preciated. CALL) at (703) 257-4500.

17 THE FORUM

BOB’S AUTOMOTIVE, Dayton, as a faulty timing chain, a Chrysler TIM'S IMPORT SALES AND SERV-

Ohio, mentions a problem with Pon- dealer reportedly replaced it for the ICE, Hutchinson, Kansas, has sub- tiac Grand Prix axle seals. The customer. Six months later, the ve- mitted a rack and pinion steering leaking seals are common, accord- hicle was brought in with the same gear from a Fiat 128. TIM'S states ing to the shop, and reportedly may problem. that the gear had no grease and ap- be due to a tolerance problem—the WAYNE’S GARAGE, Eugene, Ore- peared not to have been lubricated seals may not be large enough for gon, has submitted information on a by the factory. Due to this condi- the axle shaft. misrouted hydraulic pressure hose tion, the driver experienced a loss AABLE AUTO SERVICE, San Fran- from a 1975 Mercury Monarch with of control, although no accident re- situation, cisco, California, has informed the 21,876 miles. The hose was al- sulted. In a related the at least PRP of a timing chain problem in legedly misrouted at the factory and shop has reportedly seen a 1977 Plymouth Arrow with 24,960 lay against the exhaust manifold. four Fiat 128’s in which the rack not miles. The vehicle was brought in This resulted in a break in the hose and pinion support bushing was for service in December, 1977. and subsequent loss of power steer- properly anchored, causing a severe When the problem was diagnosed ing and power brake -ossist. shimmy.

CRACKED, SPLIT AND LEAKING FUEL HOSES: TIRE GRADING Seen Any Lately? REGULATIONS ANNOUNCED

The NHTSA has recently initiated In addition to VANOWEN, we’d Regulations for uniform tire grad- a study to review the performance like to thank ALPINE AUTOMOTIVE ing will become effective in 1979, of flexible fuel hoses used on all SERVICE, Lakewood, Colorado; LIN- according to the NHTSA. A sim- types of motor vehicles. The study COLN TECHNICAL INSTITUTE, Union, plified guide will be published along is being conducted as part of a New Jersey; BECTON AUTO REPAIR, with the ratings to aid the consumer wider project on the use of elas- Savannah, Georgia; AUTOMOTIVE in comparing treadwear, traction tomers in the automotive industry. MAINTENANCE, INC., Sarasota, Flor- and temperature resistance. Elastomers are synthetic compounds ida; W & S SERVIVE, INC., Wilming- Beginning March 1, 1979 for bias- which have the elastic properties of ton, Delaware; BOB CHESTER’S AUTO ply tires and September 1, 1979 for natural rubber but resist the action SERVICE, Arlington, Texas; CAPITAL bias-belted tires, a paper label list- of oils and fuels. Such compounds AUTOMOTIVE, Lincoln, Nebraska; ing the respective grades must be are used in the manufacture of fuel and MUSTEN AUTO SERVICE, Win- attached to the tire tread. Six hoses in order to provide needed ston-Salem, North Carolina for their months after these dates, manufac- flexibility. contributions. turers will be required to mold the Failed or about-to-fail hoses are Please send us whatever informa- grading information into the tire urgently needed. In addition, any tion you currently have on flexible sidewall. information about the brand and fuel hose problems. The treadwear grade will reflect

grade of gasoline used in the ve- the relative tread life compared to hicle would be most helpful. other types or brands of tires based The PRP has received a number upon actual performance over a test course established of cracked fuel hoses from members by the NHTSA. over the past year, most of which Traction will be identified by the symbols B, for clarity. were leaking fuel at the time they A, C A tire graded A would offer the best trac- were removed. Hoses have been re- tion. ceived from Ford, Chevrolet, Olds- Temperature resistance grades are mobile and Fiat vehicles. The most of importance to the motorist, NHTSA serious failure was reported in 1976 says, because excessively high tem- by VANOWEN BRAKE AND WHEEL, peratures can cause the material of North Hollywood, California. Al- the tire to degenerate and can re- legedly, a cracked fuel hose leaking duce tire life, leading to sudden at the carburetor end on a 1973 Ford failure. Tests for this property are caused an engine compartment fire conducted under controlled labora- which led to loss of vehicle control tory conditions to produce a com- and a subsequent accident. parative grading system.

18 6

parts return program

U S DEPARTMENT OF TRANSPORTATION • NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4, No. 2 August 1978

FIRESTONE 500 STEEL BELTED RADIALS CHARGED DEFECTIVE, SUBJECT TO BLOWOUT AND TREAD SEPARATION

NHTSA has made an initial deter- tires submitted by PRP member John mination that a safety-related defect Torvanger of John’s Union Service exists in Firestone 500 Steel Belted Bainbridge Island, Washington. The

Radial Tires. The determination is steel in the belt had come loose, the result of an investigation which eventually cutting through the tire. began last February based upon The tire had 9,804 miles. Mr. Tor- more than 500 reports of blowouts, vanger had noted six other Union tread separation, chunking, sidewall Radial Steel tires with similar prob- blisters, cracks, and out-of-round lems. conditions. The investigation un- covered over 14,000 tire failures re- NHTSA says that a comparison of sulting in 29 deaths, more than 50 Firestone’s adjustment information injuries and hundred of property with data from five other major man- damage accidents. ufacturers for comparable time pe- Problems have also been uncov- riods shows that the Firestone 500 ered in identical tires purchased from Steel Belted Radial tire has the OLDSMOBILE, BUICK AND Firestone by Montgomery Ward and highest rate of adjustment at least PONTIAC V-6s UNDER Shell Oil Company. The Wards tire two times greater—than any other INVESTIGATION is sold under the nan.e “Grappler manufacturer or tire line. Based on A safety investigation into stalling Radial” 8000 series, and the Shell production figures provided by Fire- problems in 1977 Oldsmobile, Buick tire is the “Super Shell Steel Radial.” stone, more than 1.5 million of the and Pontiac automobiles with V— In addition, the PRP has received 500 Steel Belted Radials have engines has been initiated by NHTSA. reports of similar failures in Firestone already been adjusted by the com- An estimated 445,000 cars are tires sold by Union Oil Company pany. involved in the investigation. NHTSA under the name “Union 76 Radial has received 71 owner complaints Please keep an eye out for any Steel”. The pictures which accom- reporting sudden, frequent stalling problems noted in steel belted radial pany this article are of one of three in various phases of vehicle opera- tires, including blowouts, out-of-round tion. conditions and sidewall blisters and General Motors Corp. reported to cracks. collect call Give us a or drop the agency it has received 944 com-

an information report form in the plaints from its customers. In addi-

mail if you observe such situations. tion, the Buick and Pontiac divisions have issued service bulletins to their dealers providing instructions for serv- KEEP ON CRUISIN’ icing problems described as stalling or “cold driveability.” Nine minor

The NHTSA is seeking information accidents are reported to have been on any cruise control problems which caused by this problem.

could cause a cruise control to stick, Anyone experiencing this problem

or fail to shut off or to self-activate. with a 1977 or 78 V—6 is urged to All OEM and aftermarket units on relay such information to the PRP any make vehicle are of interest. staff.

19 6

HIGH INTENSITY AUTO NEW MARKINGS FOR DEFECT 8NVESTIGATION HEADLAMPS MOTOR VEHICLE CHECKLIST The use of new high intensify CONTROLS • C8—33. Alleged Stalling of 1977 automobile headlamps that should Internationally adopted symbols Oldsmobiie, Buick and Pontiac improve drivers' nighttime seeing dis- will be required on 1981 model year Vehicles Equipped with V— tance by up to 20 percent was ap- passenger vehicles in an effort to Engines. proved by the U.S. Department of improve driver recognition, of control knobs and instrument • C8-29: 1973-1975 Pinto, Transportation. panel displays. Mustang II and Bobcat Steering Combining the best features of Symbols convey information faster Coupling Flange. and with less chance of error, American and European systems, the human said NHTSA. • C8—28: Alleged Front Wheel maximum candlepower of high-beam Bearing Failures on 1973—1977 headlamp systems has been raised Federal Motor Vehicle Safety Fiat 1 28 and X— 1 /9 Vehicles. Standard No. 101—80, issued by the from 75,000 to 1 50,000 candle- NHTSA, is effective for 1981 model ® C8— 27: Alleged Fuel Leakage power under an amendment to a passenger cars, multipurpose passen- Problem in 1975 and 1976 V-8 federal motor vehicle safety standard ger vehicles, trucks and buses with equipped Ford Granadas and issued by the Department's National a gross vehcile weight rating of less Mercury Monarchs. Highway Traffic Safety Administra- than 10,000 pounds. • C8—26. Alleged Failure of tion (NHTSA). The amendment ap- The Safety Standard will require Wiring Harness Connecting plies to both the traditional circular that most controls and displays be Rear Wheel Speed Sensor to headlights and the newer rectangular identified with specific symbols, as Anti-Lock Computer Module on systems as an option for the vehicle opposed to the present standard Ford Series B, C, F, L, W and aftermarket manufacturers. It is and which specifies words, with the use CL, 1975 to March 6, 1978. effective immediately . of symbols as an optional supple- • C8—24: Alleged Failure of ment. Noting that a large volume of Certain 13 and 14 inch Chrome traffic deaths and injuries, not fully However, words will continue to Trailer Wheels Manufactured attributable to alcohol or fatigue, be used for those controls and dis- by Broad Wheels Company. plays for which no internationally occur at night on rural roads, NHTSA • C8—23: Alleged Front Wheel agreed upon symbols have yet been said the number of such accidents Bearing and Spindle Failure Due established. might have been reduced with high to Excessive Front Brake Heat, The new standard specifies sym- intensity headlamps. Research indi- 1 975 Chevrolet Monza V—8, bols that have been adopted by the cates that the average night seeing Oldsmobiie Starfire and Buick International Standards Organiza- Vehicles. distance for speeds of 50 miles per Skyhawk tion (ISO). hour and higher is less than the • C8— 19: Alleged Breakage of average braking distance. Increas- the Manual Transmission, Floor- ing the intensity of the high-beam Mounted Gear Shift Levers in 1971—1978 Mercury Capris. headlamp systems to 150,000 candlepower should improve the night- ® C8—20: Alleged Malfunction of time seeing distance by more than Power Steering Control Valve 20 percent. in 1975— 1977 Ford Granadas and Mercury Monarchs. Glare from the new vehicle head- • lights should not be a problem, C8-04. Alleged Sticking of Idler Arm Bushing in 1968 to NHTSA believes. There is only a 1974 Fords, Lincolns and slight increase in the glare, as meas- Mercurys, Full-Size and ured by two cars illegally approach- Intermediate. ing on high beams of 150,000 • 02: Alleged Jumping Into candlepower. A reduction of seeing C8— Reverse from the “Park" Posi- 1 should distance of only .5 percent Ise Kuromi of ISE AUTOMOTIVE, tion of Certain 1970—78 Ford, i be registered as compared to to- North Hollywood, California, holds his Lincoln and Mercury Vehicles today's headlight systems with 75,000 Certificate of Appreciation as one of Equipped With C—6 or FMX candlepower. last year's special contributors to the Transmissions. PRP.

20 8

THE FORUM

WALES GARAGE, Fort Lauderdale, Mike Biderman of DOLLAR-RENT- hydro-booster failure in 1977 and Florida, has submitted information to A-CAR in Sioux City, Iowa responds 1978 Mark series Lincolns, leading the PRP on an original equipment to our June issue note regarding to a loss of power steering and power EGR plate removed from a 1975 Chevette shifters. He reports that brakes. Ford Thunderbird with 36,250 miles. he has four standard transmission Any inputs on case C8—23, Front The EGR plate, according to WALES, Chevettes and has replaced “a mini- Wheel Bearing and Spindle Failure ' had disintegrated. “As a result,” mum of 1 2 gear shift levers due to on 1975 Chevrolet Monza V— 8’s, the shop continues, “exhaust gases breakage. A New York State auto Oldsmobile Starfires and Buick Sky- escaped into the passenger compart- parts store has also phoned to report hawks would be appreciated. Chuck ment, causing nausea and drowsi- the same problem in all 25 Chevettes Broderick of AUTOMOTIVE CITY ness to the people in the car.” The in its fleet, “sometimes three or four March, 1977 PRP News reported on per vehicle.” SERVICE, San Francisco, California, this problem in 1973 and 1974 V— The LEON COUNTY SHERIFF DE- has submitted information on a 1975 Fords. At that time. Ford notified PARTMENT, Tallahassee, Florida, Monza which developed a cracked the Environmental Protection Agency reports a hydraulic booster which frame and broken wheel, allegedly that it would send letters to owners burst on a 1977 Ford LTD police due to the excessive weight of the stating that any burned plate in EGR package with 28,000 miles. The V— 8 engine. Similar problems due the 1973 and 1974 Fords would be maintenance department believes to engine weight are currently of replaced free of charge. It now that a weak seam caused the booster interest to the PRP. appears that the problem could affect to fail, leaking fluid and resulting in 1975 models and that it could be a a loss of power steering and power safety-related problem, due to the PRP Telephone Number: brakes. vehicle in possibility of carbon monoxide The was not reaching the passenger compartment. motion at the time. The PRP recently Have some interesting information? Please report any similar situations received a similar complaint from a Need more materials? CALL US to the PRP as soon as possible. Lincoln-Mercury dealership alleging COLLECT (703) 527-4500.

Contractor (• Failed Parts PRP Kappa Systems • Information > • Analyze Telephone • Compile Contacts PARIS RETURN PROGRAM Part and Information Processing

Computerized NHTSA Manufacturer Data • Owner Response Information > • Engineering Analysis > recall > • Remedy Defect System • Investigation A

WHATEVER HAPPENED TO THAT PART I RETURNED? We're often asked to describe the entire Parts Return Program process from your discovery of a failed part to a NHTSA

recall campaign ? How long does it take? What steps are involved? Is the information submitted by members really helpful? The above flowchart gives an overview of the process from beginning to end. In the coming months we'll be describing various segments of that process, beginning with the processing of parts on a day-to-day basis. We think

you'll enjoy this approach, and it may answer some of your questions about the program. Stay tuned!

21 parts return MtES O' program U S DEPARTMENT OF TRANSPORTATION « NATIONALmewsHIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vo I. 4 No. 3 September 1978

TROUBLE WITH THE TOOLS OF THE TRADE PROBLEMS REPORTED ON

In response to an article concern- jacks. These involved the handle DODGE VAN SUSPENSIONS ing scissors jack failures in the May, breaking off at the base. wheel A A & F ALIGNMENT, Long Beach, fell off one, three others 1978 PRP News, RIVERSIDE AUTO and had California, has notified the PRP of PARTS, Macon, Georgia, has for- bad hydraulic seals which would not a potential problem in Dodge van information similar allow the jack to retain hydraulic warded on a suspensions. The shop reports that failure. 1 ton pressure. The is currently The Hein Werner Vi NHTSA Dodge MB300 vans equipped with reviewing scissors jack pictured here reportedly other alleged failures of heavy duty suspension packages collapsed after its handle broke off the Hein Werner hydraulic jack. could suffer lower ball joint breakage while a vehicle being jacked up. was In July, 1977, the NHTSA initiated due to the improper fit of the ball The shop states that with this design, an investigation into the Hollywood joint stud into the steering arm. once the handle breaks off, there is Accessories hydraulic floor roller jack, Allegedly, the taper of the stud nothing left to hold the jack, result- model 646, as reported in the is not the same as the taper of the ing in complete collapse. October, 1977 PRP News. On April spindle steering arm. This reportedly In a related incident, WHEEL noti- 5, 1978, Hollywood Accessories results in a large amount of play in WORKS, INC., Marlow Heights, fied DOT that they would recall all the joint which could cause the stud Maryland, reports seven failures in- such jacks. to break. The shop says it has seen volving Hein Werner hydraulic floor Any member having information this condition on several MB300 vans,

on jack failures is one of which was equipped as an THE FORD TRANSMISSION urged to forward the details ambulance. PROBLEM to the Parts Return Pro- gram staff, either by using the Infor- In a related situation, B. W. RILEY this ever happened to Has you? mation Reporting Form or by calling ALIGNMENT AND BRAKE SERVICE, You’re pulling a customer's LTD into us collect. Springfield, Virginia, reports undue the bay area for servicing. Realiz- wear on the rear tires of some ing that you need to adjust the lift, Dodge B100, 200 and 300 vans you throw the gear selector into being brought in for repair. Vans "Park” and jump out. Moments have ranged from 1975 to 1977 later, you turn around to see your with mileages as low as 8000. customer's car backing away in Further examination of the vehicles reverse. indicates according to the shop, that It’s not impossible. NHTSA has the right rear spring hangers were had recent reports of "repeat” prob- set back % of an inch, resulting in lems of Ford automatic transmissions irregular rear tracking. jumping into reverse. As first re- Any further information on Dodge ported in the September, 1977 issue van suspension problems would be of the PRP News, the NHTSA has appreciated. been investigating such occurrences in 1973—1978 Fords, Lincolns and Mercury’s equipped with C—6 or FMX automatic transmissions. Allegedly, PRP Telephone Number: the design of the transmission is such that the gear selector lever may seem Photograph of failed Hein Werner Have some interesting information? to be fully in the "Park” detent prior scissors jack submitted by RIVERSIDE Need more materials? CALL US (continued on page 3) AUTO PARTS. COLLECT (703) 527-4500.

22 WHAT EVER HAPPENED TO THE

PART I RETURNED? (Part 1) SOME RECALL CAMPAIGNS SUPPORTED BY THE PRP A mechanic replaces a broken Regarded on the Data Sheet are: the

failed spindle is spindle. The ob- vehicle owner's name and address, • 78V070: Power Steering Hose viously problem if a safety-related and available, the relevant information Deterioration From Exhaust possibly defective. There are no on the vehicle itself, the component Manifold on 1 975-76 AMC indications that the vehicle has been classification (Steering assembly; Hornets and Gremlins. abused or in an accident. Didn’t Steering linkages— Knuckle-Spindle- • I see something about this in a recent Arm), the failure data as supplied by 77V242.- Defective Accelerator issue of the PRP News?, he thinks. the mechanic who filled out the part Pump Seal in 1975— 76 Valiants

Yes! It was currently under investi- tag, and the analysis of the problem and 1977 Volares (stalling). gation. Case C8— 23. I'll bet that as seen by the automotive analyst • 77V125: Flex-Fan Blade Break- they would like me to send in the reviewing the part. If additional in- age on 1976—77 Fords with part. Where's the mailbag? formation is needed, the mechanic will be contacted. Air Conditioning, 1976—77 Mer- So the broken spindle is dropped curys "wfth-Air Conditionirrg trrrd f into a mailbag and sent to Kappa The Failed Part Data Sheets are

1 Lincolns with c.i.d. Systems in Arlington, Virginia to be now given to the Kappa Systems 977 400 used in the NHTSA's continuing effort data transcribers and are ultimately V— 8s. to increase the level of highway entered into the automated file of • 77V105: Fuel Line Deteriora- safety. What happens to the part the Office of Defects Investigation, tion from Battery Acid on from there? along with the vehicle owner com- 1970-76 Porsche 914. As parts and information are re- plaint letters and manufacturer serv- ceived at Kappa, a daily step-by- ice bulletin information. The part • 76V160: Defective Rochester step procedure is followed. Each itself is stored for possible future carburetor fuel inlet plug on part is logged-in, with information analysis. 1966 Chevrolet and Buick. noted on the contributor, the date The same process occurs with the received, the vehicle from which the • 77V097: Flex-Fan Blade Break- information reporting forms which part was removed and the type of age on 1972 Torino, Montego, are submitted to the PRP; the only failure involved. The mailbag is Lincoln and Ranchero. difference is that, without the part, processed for further use and the no further analysis can be done. part is sent to the storage/analysis 1 • 76 V 165: Defective Steering room. The next logical step, of course, Gear Attachment Bolts on 1976

is to let you, the members, know Ford El 00, El 50, E250, E350. PACTS RETURN PROGRAM about what we’ve received. Sup- FAILED PART DATA SHEET pose, for example, that the spindle submitted had been from a 1976 articles have solicited parts and in- Monza. The investigation involves formation which, in turn, have helped support investigations that led to re- only 1975’s. If iHooked as though calls. (See the adjoining partial list it should be investigated further, we of such recalls). In essence, then, would contact the contributor and the PRP is a constant flow of infor- confirm the model year of the vehicle, mation in both directions. Your check the engine size and obtain any information report or failed part may other pertinent information which may seem isolated, a single unrepeated not reported originally. have been occurrence. But if it is a genuine

The result of this followup con- problem, others will soon respond to tact might be a news article (perhaps a newsletter reference. Suddenly, your input is no longer the isolated a short mention in the Forum) report- occurrence it once appeared to be. ing the failure and soliciting informa- Instead, it could be the first step in tion on the same problem from other uncovering an manufacturing or Here, an in-house automotive participants. Such an approach led design defect. analyst assigns each component a to a wealth of information from unique identification number and participants on flex fans during the NEXT: The Engineering Analysis/

completes a Failed Part Data Sheet. past year. In fact, many newsletter Defect Investigation Process.

23 THE FORUM

M & B AUTOMOTIVE REPAIR in A vacuum operated brake release The LEON COUNTY SHERIFF Bethlehem, PA submitted to the PRP was sent to the PRP from AUTO- DEPARTMENT, Tallahassee, FL, re- MOTIVE CITY SERVICE CENTER, San ci fuel pump from a 1978 Dodge ports difficulties with the accelerator Francisco, CA. The part was from Colt with 14,000 miles. The fuel pump diaphram installed on its 1977 a 1976 Cadillac Seville with 45,616 pump from the 1600 engine has a Ford LTD police vehicles. LEON miles. A leaky diaphragm allows broken diaphram which allows en- COUNTY claims that the diaphram is vacuum loss causing constant vacuum gine oil to seep outside the engine too small, causing stalling. The prob- noise and possible intermittent emer- vehicles, and into the ignition system. Allegedly, gency brake release. The vacuum lem has occurred on 6 this could result in loss of engine loss also allegedly causes rough en- replacement of the diaphram does power as well as a possibility of a gine idle. Similar occurrences with not appear to help. vacuum operated brake releases fire. AUTOMOTIVE CITY SERVICE CEN- should be reported to the PRP. An exhaust gas recirculation TER has also notified the PRP of a FIELDS CADILLAC, Evanston, IL, (EGR) valve from a 1977 Ford FI 00 problem with the electronic fuel in- reports stalling problems in certain was submitted to the PRP by W & S jection control unit on 1976 Datsun rental vehicles which they own. 1978 SERVICE INC. of Wilmington, DE. 280Z’s. The shop states that the Chevrolet Caprices and Buicks with The EGR value would not hold engine problem is due to failure of the out- 305 cid engines are reportedly stall- vacuum and therefore was unable put transistor. The transistor itself' ing out due to clogged original to function properly. This allegedly as equipment fuel filters. Vehicles in- reportedly cannot be purchased caused rough engine idle and valve volved have approximately 6000 a replacement part; hence the entire noise. miles. control unit requires replacement.

TRANSMISSION—Icon ! from page 1)

to actually reaching the proper slot NHTSA issued a consumer advisory sible occurrence of the problem in- in the detent plate. A slammed door on the transmission problem. The clude turning off the engine and or even engine vibration could cause advisory was issued on the basis of checking to be sure that the gear the lever to move, shifting the trans- reports involving 777 accidents, 259 selector is securely in “Park”. mission into “Reverse”. injuries and 23 fatalities. It affects All PRP members are urged to As early as 1971, the Ford Motor 9 million Ford vehicles equipped with exercise care here. The consumer Company had been receiving ap- C—6 or FMX transmissions. Precau- advisory applies to everyone! Never proximately six letters per month on tions to be taken against the pos- leave a vehicle running unattended! the transmission problem. Inter-office memoranda obtained from Ford by the NHTSA indicate that Ford engi-

neers had noted the difficulty in late

1971 and had suggested, in early 1972, two possible fixes which ad- dressed the problem. One approach was to angle the detent plate between Park and Reverse and to angle the tang of the shift lever. These corrections would have forced the

lever to travel uphill in order to slip

into “Reverse” from “Park”. in addition, an angular force would

hold the lever in place, even if it

were not fully in the “Park” position. The second remedy involved increasing the angular travel between “Park” and “Reverse” through a

revision in the transmission design. George Casper and his staff in front of their shop, AUTO BRAKE CORPORA- Apparently, neither approach was TION, Norfolk, Virginia. Auto Brake was one of the winners of last year's adopted, and late in August, the Certificate of Appreciation from NffTSA Administrator Joan Claybrook.

24 r

parts return program

U S DE PARTMENT OF TRANSPORTATION • NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4 No. 4 October 1978

FILLER NECK LEAKS IN JEEP VEHICLES RECENT RECALLS AND

The National Highway Traffic nections with No. 2 Permatex or INVESTIGATIONS Safety Administration has received equivalent. Any PRP members who NHTSA has opened an investiga- some reports involving the fuel tank have noted this problem should con- tion of 1977 Porsche 911’s which filler neck components of some 1975 tact the PRP as soon as possible, allegedly experience engine com- and later Jeep Wagoneer and Cher- particularly any instance in which partment fires possibly caused by okee vehicles. gas has puddled in the rear quarter the vehicle’s air conditioning units. Cool gasoline from service station panel or a fire has started. Porsche recalled a number of AC storage tank can warm up and ex- equipped vehicles in October 1977,

pand in the vehicle’s tank causing it however a number of reports of fires to fill up the filler neck components. have been received from owners of

If the component points are not prop- 91 1 vehicles, prompting further in- erly sealed, the gas may leak out. vestigation by NHTSA. Also, gasoline may come out of the Subaru of America has announced filler cap vent (the vent opens if 1 a recall of the 1978 brat vehicles psi pressure exists in system) and run due to alleged fuel tank leakage. back inside the body if the filler A blockage in the fuel evaporative neck flange does not seal the hole control system may lead to abnor- in the body. Gasoline odors inside mally high pressure in the fuel tank the car may indicate a leak exists. which could cause hairline cracks The recommended repair by Jeep and leakage. involves removal of the left rear quarter trim panel, loosening the con- The Ford Motor Company is re-

nection clamps and sealing the con- calling approximately 400,000 of its 1978 Ford Fairmont and Mercury MULTI-PIECE WHEELS Zephyr vehicles for replacement of the The NHTSA has recently initiated jectile.” In a report to the NHTSA, windshield wiper linkage. NHTSA urged Ford to conduct a recall cam- an engineering analysis into multi- the Insurance Institute cited a number piece wheels paign after receiving information commonly found on of serious injuries and fatalities. The trucks, motor homes buses. In concerning windshield wiper failures and NHTSA has prepared a ‘‘safety chart” addition, rulemaking on these vehicles. Owners of ve- to govern con- and a “matching chart.” These charts struction of these wheels has been hicles built before April 26, 1978 illustrate the proper safety precautions initiated. The wheels allegedly are will be notified to return their vehicles that should be followed when serv- prone to if blow apart the ring and icing multi-piece wheels, and provide to their dealer for replacement of rim base are not properly assembled. information on the safety interchange- the linkage with that of a later de- According to the Insurance Institute ability known to exist among various sign. for Highway Safety, ‘‘if the compo- multi-piece wheel makes and com- nents of a multi-piece wheel are not ponents. PRP members who work perfectly alinged in the assembly with these wheels may obtain these MOVING to a bigger shop or a process or if they become misaligned charts by calling the PRP COLLECT better location? Let the PRP move by any number of common occur- (703) 527—4500. Additionally, we with you. Call us collect when you rences, including the normal opera- urge our members to report any prob- have a change in address so you tion of the vehicle, an explosion can lems they have encountered with won't miss an issue of the PRP News. occur, making the ring a lethal pro- these wheels. (703) 527-4500

25 — 6

WHAT EVER HAPPENED TO THAT DEFECT INVESTIGATION PART I RETURNED? (Part 2) CHECKLIST

1*111’ Conlnicloi I'mlt'il r»rlH • Kiippu SyHlumu C8-33. Alleged Stalling of 1977

In ft • i'hi nt Inn > • Aniily/.r Oldsmobile, Buick and Pontiac

IVloplioiu 1 • Compile (‘••ill min PARTS RETURN PROGRAM Vehicles Equipped with V— Engines. Part and Information Processing • C8-29: 1973-1975 Pinto,

Mustang II and Bobcat Steering V Coupling Flange.

Manufacturer Owner itesponse • C8—28: Alleged Front Wheel recall -> > Remedy Defect Bearing Failures on 1973— 1977 Fiat 128 and X— 1/9 Vehicles.

A • C8—27: Alleged Fuel Leakage

/ Other i Problem in 1975 and 1976 V-8 /information / equipped Ford Granadas and Mercury Monarchs. Last issue we traced the journey auto safety hotline inputs, and recall of a failed part from its discovery by information. The information system • C8—24: Alleged Failure of a mechanic to its entry into the is then employed by the Engineering Certain 13 and 14 inch Chrome NHTSA information system. Now Analysis Division for purposes of Trailer Wheels Manufactured we’ll take a look at the engineering analyzing the data, isolating trends, by Broad Wheels Company. analysis/defect investigation process and gathering information. • C8-20: Alleged Malfunction of within the NHTSA, which can even- Once the engineers of the Engi- Power Steering Control Valve tually lead to a recall. neering Analysis Division conclude in 1975— 1977 Ford Granadas The National Highway Traffic that there may be safety related con- and Mercury Monarchs. Safety Administration is a multi-fac- sequences to a particular trend, they • C8—04. Alleged Sticking of eted organization. Within the agency contact the manufacturer for further Idler Arm Bushing in 1968 to there are six associate administra- information such as warranty data, 1974 Fords, Lincolns and tions, reporting directly to the NHTSA sales of a particular part, etc. Care- Mercurys, Full-Size and Administrator Joan Claybrook. Among ful review of all aspects of the prob- Intermediate. the most important of these, from the lem is made. Vehicle component point of view of the PRP, are Rule- testing is conducted in some cases. • C8—02: Alleged Jumping Into making and Enforcement. The As- At this point, all information gath- Reverse from the "Park” Posi- sociate Administrator for Rulemaking tion of Certain 1970—78 Ford, ered is presented to a Defects Review is responsible for vehicle safety stand- Lincoln and Mercury Vehicles Panel. The panel determines whether ards and automotive fuel economy Equipped With C-6 or FMX or not a full investigation should be standards. The Associate Admin- Transmissions. initiated. If an investigation appears istrator for Enforcement is responsible for fuel economy compliance, vehcile to be warranted, the Defects Evalua- safety compliance and defects in- tion Division then takes over. The report is written, with a recommenda- vestigation. It is in this last office manufacturer is notified of the inves- tion to the NHTSA Administrator. the Office of Defects Investigation tigation and is requested to report to The Administrator then makes an that PRP inputs are brought into the the NHTSA any information relating initial determination if a safety de- investigation process. to the case. Further tests may be fect exists. A public hearing is held The Office of Defects Investigation conducted on the vehicle, part (or and a final determination made. If (ODI) is further broken down into design) in question. Interviews are a defect is declared, the manufac- the Defect Information Systems Staff, undertaken with individuals who have turer who may voluntarily recall at the Defects Evaluation Division and reported a problem. At this time, any time, is ordered to conduct a the Engineering Analysis Division. accident reports are collected, pri- safety recall campaign. Should he Here's how the flow of information disagree with this finding he vate engineering analyses are re- may works. PRP inputs are received into ask that the case be reviewed in viewed, medical records are obtained the system by the Defects Informa- federal district court. tion Systems Staff. There the input (in the case of injuries) and repair Next: The Recall Campaign. is combined on file with manufacturer receipts gathered. Once all the service bulletins, consumer letters. facts have been assembled, a final

26 THE FORUM

ELMHURST AUTO PARTS, Elmhurst, portedly leaking gasoline. The other, is currently looking into Ford EGR Illinois, has submitted a fuel pump leading from the pump, had rup- spacer plate/exhaust fume problems from a 1976 Ford truck with a 460 tured. and any information you might have dia- cid V— 8 Engine. The pump The PRP has received twelve car- would be helpful. phragm reportedly broke, allowing buretor floats this month from par- WALES GARAGE, Fort Lauderdale, gasoline to enter the crankcase and ticipating members. All floats received Florida, has submitted to the PRP a with the engine oil. mix were reported to have suffered gas timing belt from a 1976 Chevette PEDLEY'S GARAGE, Owensboro, saturation, which caused flooding, with 15,943 miles. The belt was re- Kentucky, reports a possible design stalling, and overall poor engine ported to have failed while the ve- problem in a 1971 Ford LN600 with performance. These inputs were in hicle was in motion. FRANK’S 140,000 miles. The tank is made of response to the carburetor float sat- AUTOMOTIVE has also noted a tim- a plastic material and is mounted uration report in the July, 1978 PRP ing belt problem in a 1976 Chevette very close to the muffler. A heat News. The contributing shops were with 1 8,733 miles. The shop main- shield is between the tank and muf- RICHARDS AUTO SERVICE, Los An- tains that the metal gears were worn fler, causing direct heat to be applied geles, California, SUBURBAN AUTO- by the belt teeth to such a degree to the shield. The temperature was MOTIVE, Lynwood, Washington, and that the belt jumped timing. sufficiently high to melt a 2 x 6 inch AUTO BRAKE CORPORATION, Nor-

hole in the fuel tank, creating the folk, Virginia. possibility of a fire. Similar occur- FRANK’S AUTOMOTIVE SPECIAL- rences are of interest to the PRP. The NHTSA has received 10 re- IST, Montour Falls, New York, has ports of liquid gasoline spewing out Please report any of which you are submitted two Ford EGR plates which aware. had corroded. One of the plates of the filler neck when the gas cap is removed on late model Volvos. In response to an article in the was removed from a 1 973 LTD with July, 1978 PRP News, W & S SERV- 37,000 miles. The deteriorated EGR Other reports of this problem are

ICE, INC., Wilmington, Delaware, plate caused a hole to develop in urgently being sought.

has submitted two fuel lines. Both the carburetor base plate. This al- Late model Volvos have also been were removed from a 1973 Buick legedly caused the carburetor ex- reported as stalling due to vapor lock

Electra with 27,000 miles. One hose, terior to become fuel-soaked, creating in the fuel lines. Additional reports

leading to the fuel pump, was re- a potential fire hazard. The NHTSA of this problem are also of interest.

The End of the High Speed Chase?

The Department of Transportation designed to provide additional infor- nate confusion on the part of mo- has recently concluded that high mation or instruction for operators torists. speed operations by police and emer- who have already passed the defen- 3. Training should be expanded gency vehicles are a threat to high- sive driving course, should be avail- to include special training and licens- way safety and should be more able in late fall. ing of emergency response vehicle closely controlled and monitored by A report issued by the Connecticut operators, with police officers receiv- local authorities. The NHTSA Admin- ing additional training in high speed istrator, Joan Claybrook, suggests safety commission showed 344 emer- pursuit driving. that “immediate action is needed to gency vehicle accidents in the state more accurately determine the de- during 1976 with 10 persons killed 4. Increased penalties for those

gree and severity of problems asso- and 321 injured. In 1975, 343 ac- attempting to flee from the police at with ciated high speed chases." cidents resulted in 6 deaths and 298 high speeds. To help alleviate some of the injuries. 5. Adoption by police departments danger in high speed operations, the The Commission's findings included of a specific detailed policy for of- NHTSA has developed a drivers' the following recommendations: ficers involved in high speed pursuit, course for operators of emergency

1 . Emergency vehicles following the state policy vehicles which would include an ex- response as a guide. should be clearly defined by state planatory guide to the course, an 6. Institution of a public informa- law. instructor's manual and lesson plans, tion campaign to advise motorists of

and a trainee study guide for emer- 2. Lights on all emergency vehicles their responsibilities towards emergency vehicle operation. The course, should be of uniform color to elimi- gency vehicles.

27 parts return program

u s DEPARTMENT OF TRANSPORTATION • NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4, No. 5-6 November-December 1978

GM RECALLS 1975 U.S. DEPARTMENT OF TRANSPORTATION MONZA STARF8RE, NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION WASHINGTON. DC. 20590 SKYHAWK

General Motors recently an- THE ADMINISTRATOR

nounced that it will recall some 130,000 1975 V— 8 equipped Chev- Dear PRP Member: rolet Monzas, Oldsmobile Starfires

and Buick Skyhawks for a front wheel I want to take time out thia holiday season to thank all of you for your participation in our Parts Return Program (PRP), particularly bearing problem. As reported in the those of you who have been active participants this past year. May 1978 issue of the PRP News, grease may not be adequately re- We are very proud of the PRP and the contributions it has made to motor vehicle safety. As many of you know, the Program has now been in tained in the front wheel bearing operation for over 7 years. During that time, over 7,000 failed under heavy brake application, due automotive components and information have been received from approximately participants. These components and the related to the heat softening the grease. 700 information have been crucial to the support of many of our safety GM received three reports of acci- defect investigations and resultant recalls, and have served often as dents and one injury due to this early warning indicators of vehicle safety problems. Please take a moment today and jot down on the Information Report form any condition. information concerning a possible vehicle or equipment defect that you The remedy will entail the addition may have noticed in the last few days. Drop it in the mail to us, and let the manufacturer know as well, so that we can all work to improve of newly developed grease retainers motor vehicle safety. Believe me, data from you can do more to isolate and seals in the front wheel hubs to a problem in its early stages than from any other source. improve grease retention. GM has I want to also mention that we have received enthusiastic response from indicated that new outer wheel bear- new car dealers, fleets, and automotive parts suppliers about joining ings will be installed and inner ones the Program. Almost 90% of those visited expressed their interest in joining the PRP. checked for damage. All bearings will be repacked with the recom- Again, I thank all of you for your support. mended GM grease. Parts should be available in January 1979, at which time owners will be notified. Joan Claybrook Special thanks to FARRELL'S SU- NOCO STATION, Fairview Village,

SPEED 1 Pa., who contributed parts from a '75 LIMIT Monza. Thanks also to our other members contributed related It's a law we who can live with. info.

PICTURE IT

A picture is worth a thousand tion on parts or failures that are In addition, many of the photos

words (well, maybe not that many) repaired on the vehicle. Frame contained in the News have been but not a single part. cracking is a good example. They sent in by members. Next time you We have noticed an increase in are also a good way to show the have a part that must be returned to the number of photographs accom- extent of damages caused by a fail- the customer or manufacturer, can- panying failure reports and we like ure, a fire for instance. A report with photos carries not be removed, or is too big to send it. Many have been the Polaroid or documented more self developing type. Photos are par- weight should an investigation into in, "picture it" with your info report. ticularly useful in conveying informa- the problem be opened.

28 NHTSA STEPS UP INVESTIGATION FIRESTONE 500 OF VW RABBIT MASTER CYLINDERS RECALL UPDATE

As originally reported in our May, A description of the circumstances On October 24, 1978, the Na- 1977 issue of the PRP News, the PRP surrounding the failure is also quite tional Highway Traffic Safety Admin- has received a number of reports re- important. For example, did the istration (NHTSA), received the garding problems in VW Rabbit mas- pedal go to the floor? Was there a agreement from the Firestone Tire ter cylinders- Since that time, forewarning such as sluggish braking and Rubber Co., calling for the recall numerous complaints have been re- action? gradual wear? Was the of Firestone Steel Belted Radial ceived by the National Highway 500 warning light on for a period of time Traffic Safety Administration (NHTSA) Tires and Firestone TPC Steel Radial before the failure occurred? Did an on Rabbits and other models indicat- Tires under the terms announced on accident result? ing a widespread problem. October 20.

For this reason, the NHTSA is ex- Along with information on the cir- In announcing the recall, Secretary tending its inquiry into VW master cumstances of the failure, please note of the Department of Transportation cylinders to include 1975—78 Rabbit the following items as well: vehicle remarked "it is fashionable today to Scirocco master cylinders, and and identification number, mileage at fail- attack the government's regulatory 1974—78 Dasher and Audi master ure, vehicle model, whether the part powers. The Firestone case, however, cylinders. was original equipment or a replace- shows the wisdom of allowing citizens help on this review is urgently Your ment, whether the part had been re- to use their government to force ac- needed. The NHTSA requests any placed more than once, etc. failed Rabbit, Scirocco, Audi and tion that they could not gain as indi- If the part is not available, please Dasher master cylinders for testing viduals". record all information on the infor- purposes. Please do not disassemble The fires involved in the recall are the cylinder before sending it to the mation report form and send it as those Steel Belted 500's made with PRP. soon as possible to the PRP. the five-rib design manufactured be-

fore Jan. 1, 1977. The 500's made with the seven-rib design and TPC

radial tires will be included if manu-

factured before May 1, 1976.

The Parts Return Program would

like to give special thanks to those

members who have contributed to the case by information they have come across. These members are GOTHAM AUTO LEASE, New Ro- chelle, NY, AUTOMOTIVE CITY SERV- ICE CENTER, San Francisco, CA, 1979 GAS MILEAGE GUIDE value previously named "city" esti- JOHN'S UNION SERVICE, Seattle, mate is now called the "estimated WA, SCHUBERTS AUTO SUPPLY, Free copies of the first edition of mpg." Studies showed that of the Poughkeepsie, NY, HENNIKER AUTO- the 1979 Gas Mileage were made three previous values, the city number MOTIVE, Henniker, NH, and A&A available to the public the first week was the closest to the actual average AUTO SUPPLY, Boulder, CO. in November. The Departments of fuel economy in real driving. Energy and Transportation have com- New car dealers are required by piled information pertaining to new law to display the guides in their TELEPHONE CALLS cars, station wagons and light truck showrooms and to keep an adequate models and the estimated miles-per- supply on hand. Bulk copies can be If you have information for the gallon rating for type of vehicle. each requested from Fuel Economy Distri- PRP or are in need of supplies, please The 1979 edition no longer gives bution, Office of Administrative Serv- give us a collect call at 703/527—

the values previously called "high- ices, Department of Energy, Wash- 4500. We'll be more than happy to way" and "combined" mpg. The ington, D.C. 20545. take the information over the phone.

29 WHAT EVER HAPPENED TO THAT PART I RETURNED? PRP MEMBERS RESPOND PART in TO AMPLIFIER PROBLEMS

|>lt P Coni motor In the April, 1978 issue of the PRP Kappa Systems InforniMl Inn — - ^ • Analyze News, failure of Ford ignition ampli- • Compile Contacts / PARTS RETURN PROGRAM fiers was discussed. More inputs

Part and Information Processing have been received by the PRP re-

garding this. Wayne Wheeler of

v WAYNE'S GARAGE in Eugene, Ore- gon, submitted to the PRP an ignition • Owner Response -> • Remedy Defect amplifier from a 1978 4-cylinder Ford

Pinto with 20,218 miles. The car

stalled and could not be restarted.

Several checks were run on the igni-

tion amplifier with no positive results.

Last issue we considered the engi- tivate an owner to get his vehicle The amplifier was replaced, and this neering analysis/defect investigation inspected or corrected as soon as pos- apparently corrected the problem. process within the NHTSA which can sible. This letter must contain: (1) lead to a recall. Our concluding a description of the defect, (2) an Mr. Robert L. Leu, Parts and Serv- article in this series shows what steps evaluation of the risk involved, (3) ice Manager at V & H FORD in are required of the manufacturer by what action will be taken to remedy Marshfield, Wisconsin also mentioned the National Traffic and Motor Ve- the defect, (4) state that it will be hicle Safety Act (the Act), and sup- without charge, (5) state when the that he was aware of a problem. porting regulations. parts or remedy will be available Larry Fox of FOX AUTOMOTIVE in First, the manufacturer submits to and in the case of tires, the time limit Tulsa, reported to the PRP NHTSA a defect information report (60 days) in which they must be re- Oklahoma which outlines what vehicles and how placed and (6) the procedures to con- an explanation of a problem, which tact NHTSA if unreasonable difficulty many are affected, a description of he has also seen. Sometimes the the defect, and a description of the is experienced in obtaining corrective resistance wire on the amplifier which corrective measure to be taken. The action.

carries approximately 1 .6 ohms re- manufacturer then has three options Is the manufacturer’s obligation to remedy the defect: (a) by repairing limited in any way by the Act? Yes, sistance can crack internally and the vehicle without charge, (b) by in the case of a vehicle over 8 years thereby cause an intermittent connec- replacing the vehicle with reason- old, the is not a manufacturer bound to tion. Visual inspection cannot detect ably equivalent one, (c) by refunding remedy the defect without charge. this crack. Electrical testing of this the purchase price less allowance for This is 3 years in the case of tires. possible cause should be included depreciation. In the case of replace- There is also no provision in the Act before an entire unit is replaced. ment equipment, this can only be for reimbursement of, (a) damages or repaired or replaced, with refunds. no expenses incurred as a result of a Donna Foran of TIM’S IMPORT In most cases, a vehicle is modified defect or, (b) expenses to repair a SALES AND SERVICE, Hutchinson, to prevent a failure, or to preclude defect prior to the official determina- Kansas, reports a failed ignition am- any safety consequences as a result tion that it exists. of the failure. plifier from a 1975 MGB Roadster Now, if all this sounds legalistic, it with 34,000 miles. The failure of Once the manufacturer has elected is. We hope though, that by reading this one of these options he then notifies this article you have gained a better component caused intermittent

dealers of the upcoming action. understanding of what a safety recall stalling of the vehicle. Dealers must receive equitable reim- is all about. We hope that this series The NHTSA is currently looking bursement for their efforts in perform- has given you an idea of the special ing the action. into problems with Ford ignition am- correction part you play in the process. NHTSA

Next the owners are notified by needs the knowledgable, timely re- plifiers and needs whatever informa-

first class mail. The letter should mo- ports that only you can provide! tion is available from the field.

30 AMC VACUUM ADVANCE FAILED PARTS, NO PARTS

ROPE GARAGE, Cibolo, Texas, re- B. W. RILEY ALIGNMENT AND ers in the east were reportedly not • ports a distributor problem on a 1977 BRAKE SERVICE of Springfield, Vir- stocking OEM parts for two year old ginia, has contacted the regard- American Motors Pacer. The spring PRP vehicles. It was explained to the ing the brake power booster unit on holding down the distributor cap was, PRP that this is a common occurrence Chevrolet Luv pick-up trucks. Riley’s according to the shop, catching on a often causing inconvenience for the encountered a 1976 Luv pick-up suf- wire and causing an electrical short. shop as well as the shop’s customers. fering from erratic braking. The The result—complete engine shut- apparent problem, according to the down. A ruptured vacuum advance shop, resulted from the breaking of diaphragm was also reported. Although the PRP can do nothing the master cylinder pushrod on the directly to help, we may be able to The NHTSA has reports that a rup- atmospheric side of the diaphragm pass along info from our member tured diaphragm can be responsible in the power booster. The pushrod shops, part suppliers and dealers for the distributor cap blowing off in reportedly comes apart in the rubber, concerning some hard to find parts. some 1975—76 AMC vehicles. When and Riley’s has seen this in other Luv vehicles before. Let us know what you think. Part the engine is shut off, a vacuum in suppliers, dealers: If an item which the cap draws an air fuel mixture After diagnosing the problem and could cause safety problems suddenly that replacement part from the intake manifold into the dis- determining a be obtained, Riley's was faced with becomes a hot seller, let the PRP tributor. On restarting, the distribu- still another problem; no parts could know. It could indicate the start of tor cap can blow off due to the be located on the east coast. Deal- a widespread problem. combustible mixture. If this happens often enough, the springs holding the cap can weaken and may need re-

placement. Replacement clips are available from AMC, we understand.

If you note this problem, the first

place to look is the vacuum advance unit. Next, please report the infor-

mation to the PRP. Thanks.

UNIROYAL TIRES

Joyce Lyons of American Hospital

Supply/Scientific Products Division in

McGaw Park, IL reported problems involving two Uniroyal tires. The tires were Uniroyal Steel Belted radials, size HR78— 15, both on the

same vehicle. These tires developed belt separation (one at 32,000 miles Recently, the PRP received a letter from Frank Hornyak, a former director of the other at miles), which 49,000 the Ohio Chapter of the Independent Garage Owners of America, Inc., (IGO). created balancing and alignment Mr. Hornyak, who has retired from the service industry, provided us with photo- to the under-carriages problems. A rough ride brought at- graphs and information concerning corrosion damage

of vehicles exposed to salt and other ice preventive road additives. . The tention to the tires. If you have photograph shows a vehicle which reportedly came apart at the front door

encountered similar problems with posts as it was hoisted on a front end lift. Hornyak commented that this is a common hazard particularly where salt and other chemicals are utilized for ice any steel radial tires, please send us and snow removal. With winter on the move, all PRP members should be the information. aware of potentially dangerous corrosion situations.

31 8 18

THE FORUM DEFECT INVESTIGATION WALES GARAGE in Fort Lauder- AUTO HOSPITAL, Lincoln, Ne- CHECKLIST dale, Florida has contacted the PRP braska, reported to the PRP a 1978 • C9—01: Alleged steering gear regarding an plate from a Ford Dodge Pickup (150 series) that had EGR attaching bolt failures on 1974— apparently been delivered from the vehicle with 48,000 miles on the 77 Ford vans and light trucks. factory with a broken coif spring and odometer. The metal of the plate • C8-39: Alleged engine compart- bent frame. The third coil from the was eaten away causing engine ment fires on 1977 Porsche 91 bottom of the right front spring was stalling periodically. Wales installed vehicles. broken, causing a hard ride and dif- a replacement. ficult steering. The vehicle was • C8—33. Alleged Stalling of 1977 Also received from Wales' Garage driven for approximately three weeks Oldsmobile, Buick and Pontiac was information concerning the cruise before the problem was discovered Vehicles Equipped with V-6 Engines. controls on Lincoln Continentals. The and repaired. • vehicle in question was a 1973 Conti- Dave Miller of ROXBURY GARAGE, C8-29: 1973-1975 Pinto,

Mustang II and Bobcat Steering nental Mark IV with approximately Roxbury, CT, has submitted to the Coupling Flange. 50,000 miles. The shop reported PRP information and photos concerning a 1977 Plymouth Volare with • C8—28: Alleged Front Wheel that the control would not shut off by 19,000 miles. The vehicle is equipped Bearing Failures on 1973—1977 stepping on the brake or by operat- with a 318 2bbl. engine which was Fiat 128 and X—1/9 Vehicles. ing the switch on the steering wheel. ‘skipping’ and running rough at idle • C8—27: Alleged Fuel Leakage This condition has been seen on other and low RPMs. The problem had Problem in 1975 and 1976 V— Ford vehicles equipped with cruise been experienced since the purchase equipped Ford Granadas and control, by the shop. of the car. Roxbury Garage removed Mercury Monarchs. Lee Davis of L.A.D. Auto Electric in the carburetor and a hole was dis- • C8—24: Alleged Failure of Spokane, WA, has submitted to the covered in the lower section of the Certain 13 and 14 inch Chrome PRP several turn signal switch assem- right hand side intake barrel of the Trailer Wheels Manufactured by Broad Wheels Company. blies, primarily from Ford products, manifold. This hole was allowing exhaust gas to continually enter the • where one or more turn signal indi- C8—20: Alleged Malfunction of intake as if the EGR valve (which was Power Steering Control Valve cator or brake lights fail to operate. in fact operating normally) was con- in 1975-1977 Ford Granadas In some cases, there is a short of stantly open. The shop corrected the and Mercury Monarchs. some kind however, the fuse did not problem by tapping and installing a • C8-04. Alleged Sticking of blow. This can cause the wire to get y<" plug. Idler Arm Bushing in 1968 to hot and in some cases melt the syn- 1974 Fords, Lincolns and thetic covering. The shop believes Mercurys, Full-Size and that one possible problem is that the Intermediate. The BRAKE SHOP in East Norwalk, switches are not compatible with the Connecticut, has submitted photos • C8—02: Alleged Jumping Into recommended fuse amperage. from the "Park” Posi- documenting a problem they en- Reverse tion of Certain 1970—78 Ford, Bill Duncan of Duncan's Auto in countered with Dodge 300 series Lincoln and Mercury Vehicles Phoenix, AZ, reported to the PRP a vans. When turning the steering to Equipped With C—6 or FMX possible problem with either extreme, the disc brake caliper 318 V— Transmissions. equipped Plymouth Volares. The hits the frame. This forces the piston back into the caliper. Upon the first problem involved a 1976 Volare ring brake application after such a and pinion gear assembly. The ring ma- New bumper brackets (P 4039246(R) neuver the brake pedal goes to the gear attaching bolts backed out and and 4039247(L)) are available for floor. Subsequent pumping will re- locked the ring against the housing. 1973-1977 Vi models. The prob- turn the brakes to normal. This caused the vehicle to stop in the lem has also been cured by using the middle of the street. The shop be- Dodge is evidently aware of the original heavy duty stop which is cast lieves that problem as they issued a service the ring and pinion gear (P 40329789). The NHTSA is cur- seems too small (7%") for the V-8 bulletin and changed the steering/ rently looking into this problem and engine drive train. jounce bumpers on the 1 977 model. a decision is expected soon.

32 CITY OF SAN JOSE POLICE PATROL FIRE

The City of San Jose has submitted The officer immediately left the ve-

to the PRP information and photos of hicle, but the running engine caused

a 1976 Dodge Monaco Police Patrol more fuel to be continually pumped by vehicle which had been destroyed out, feeding the fire and ultimately engine compartment fire. The an destroying the vehicle. 440 cid engine, was equipped with The San Jose maintenance depart- a Carter Thermoquad four barrel carburetor in which an unsecured ment is now installing safety wires to tapered plug had come out, allowing secure these plugs in place, as shown

gasoline to flood over the engine. in the photo. The PRP would be in-

The vehicle was still parked with the terested in any information concern- engine running when the plug reporting similar experiences from other edly came out and started the fire. program members.

ASPEN-VOLARE CASTER/ CAMBER PROBLEMS

Recently, 1976— 1978 Volare and Aspen models were recalled by the

manufacturer to install support brackets to reinforce the front suspension pivot bar attachments.

These brackets partially cover the

holes in the pivot bar plate used when adjusting the front end caster/ camber, making adjustments with

conventional tools difficult. The manufacturer has developed a special

tool which will overcome this prob-

lem in adjusting caster/camber.

However, the PRP has received in-

formation involving difficulty in front- end alignment on these vehicles.

Even with vehicles in which these spe-

cial support brackets have not been

installed, shops have experienced

difficulty. Reportedly, there is lack

of sufficient range for adjustment on

the upper control arms to allow for

proper caster/camber settings. Dick

Thompson of STOP & GO in Portland,

Oregon has seen this problem on several vehicles as did ROBERTS AUTO

REPAIR in Chicago, IL. If you have experienced front-end alignment problems on Volares or Aspens,

please let us know what you found.

33 r

parts return program j ADMINISTRATION U S DEPARTMENT OF TRANSPORTATION • NATIONAL HIGHWAY TRAFFIC SAFETY

Vol. 4 No. 7 January 1979

DODGE BRAKE TRIUMPH TR-7 FUEL PUMPS

PROBLEMS REVISITED TIM’S IMPORT SALES AND SERV- intermittent leak. At times, there will

Remember our article about Dodge ICE in Hutchinson, Kansas has for- be no leaking, but at other times vans experiencing brake piston-freeze warded to the PRP two leaking fuel fuel will spray out into the engine

up, as reported in the PRP News, pumps, one taken from a 1975 compartment.

June, 1978? The problem was re- Triumph TR— 7 with 18, 079 miles and Besides creating abnormal engine the other from a 1976 with ported on 1 977 Dodge B— 200 and model operation, whenever a situation in- B—300 vans with brake pistons re- 26,563 miles. The owner of one of volving fuel leakage occurs, there these portedly made of a lightweight metal vehicles noticed puddles of gas- is a potential fire hazard. Because oline alloy anodized with a surface similar where the car had been parked. the pump is crimped together, there

first to teflon. This month the PRP has The shop checked all fuel lines is nothing to tighthen to prevent or received a failed brake caliper piston and after finding no leaks, investi- eliminate the leak and the entire from a 1977 Dodge Aspen. The gated the fuel pump. Because the pump must be replaced. Any infor-

Aspen piston has a smaller surface leak was not continuous, the problem mation of similar failures in TR—7’s, diameter than the B—200 and B—300 was difficult to diagnose. should be forwarded to the PRP.

van pistons; the material, however, Fuel pumps for the Triumph TR— 7, appears to be the same. as shown in the picture, are de-

According to the shop which sent signed to be assembled by crimping the piston, JONES SERVICE, Delmar, the pump cover to the main housing.

New York, the vehicle suffered a loss Tim’s reports that this does not make

of braking power as a result of brake a seal sufficient enough to prevent

fluid leakage due to a “flat spot” fuel leakage.

worn on the piston surface. Bud According to the shop, through Jones, owner of JONES SERVICE, normal use, the crimped seal of the notes that fluid leaked out along the pump can work loose, creating an piston's flattened area, ultimately causing the brake loss. He points FORD LIGHT TRUCK AND VAN INVESTIGATION out this could possibly be the result A suspected safety defect in the million of these trucks in use, and the of uneven brake pad wear over steering systems of Ford light trucks NHTSA has received 26 reports of time, causing the piston to move out these failures. of the cylinder on an angle. Such and vans produced from 1974 In a related case, the American erratic piston travel could possibly through 1977 is being investigated Automobile Association has requested cause a flattening of the piston sur- by the U.S. Department of Transpor- in its December issue of "Let's Talk face. tation. The investigation is centering Road Service" information concern- The NHTSA is currently looking on Ford E series Econoline vans and ing cracks in the frame flange under into Aspen brake problems and F series light trucks which may suffer the steering gear box in Ford F—350 would appreciate any additional in- steering loss when the steering gear trucks. These cracks may extend up formation from members. box separates from the frame. The to the lower steering box attachment problem may be preceded by loose- bolt.

ness in steering response; however, TELEPHONE CALLS If you have experienced any of Call us COLLECT at steering loss may occur without warn- these problems, please report them

( 703 ) 527-4500 ing. There are an estimated 1.3 to the PRP as soon as possible.

34 SAFETY STANDARDS CHILD RESTRAINT SAFETY FOR LIGHT TRUCKS AND VANS The National Highway Traffic The NHTSA said three simple rules Safety Administration (NHTSA) re- can greatly improve a child’s safety The increasing fatality rate for oc- cently anounced it plans to hold a while riding in a motor vehicle. cupants of light trucks and vans has National Child Automobile Restraint Whenever a child is in a car, parents prompted NHTSA efforts to amend Safety Conference this spring to help should remember to: various motor vehicle safety stand- save the lives of more than 2,200 1. Insure that safety belts or child ards for such vehicles, effective children under the age of 14 who are restraints (for children under five 1 September 1980. killed each year in motor vehiclp ac- years of age) are always used. NHTSA figures indicate a 25 per- cidents. 2. Make sure that children sit in cent jump in fatalities for this vehicle Joan Claybrook, Administrator of the rear seats. category between 1975 and 1977, the NHTSA, said statistics indicate 3. Never leave the hatchback as compared to an increase of only that “approximately 1,000 children open when a child rides in the back percent for 3.9 passenger cars. In up to age 5 are killed and 100,000 of a car. addition, the federal safety agency in this age group are injured annually found that 1975 “If these simple rules had been and 1976 model in motor vehicle accidents. Many of two-thirds the year light trucks followed, more than of had 21.9 fatalities, these deaths and injuries could be children killed in motor vehicle acci- against 1 1 .7 fatalities per million prevented or reduced in severity if miles for dents would still be alive today,” passenger cars of similar the children were restrained so that weight. Claybrook said. they are not thrown against the ve- The NHTSA said an unrestrained The difference between these fa- hicle interior during a crash. child in the front seat of a car is tality rates can be reduced, NHTSA Following the planned national times likely to killed or said, by extending three of the safety three as be conference, the NHTSA also will con- standards seriously injured in a crash as a prop- already applicable to pas- duct 10 regional seminars on the sub- seat; senger cars to light erly restrained child in the rear trucks and vans ject of child restraints. in children with a gross vehicle weight rate of yet fewer than one 20 five are properly restrained in 10,000 pounds or less. These stand- under ards involve improved interior pad- a child restraint. ding to protect occupants, improved The sketch below shows the proper protection for the driver from the installation of child restraints in the steering control system in the event rear of a vehicle. of an accident, and limiting the distance the steering unit can move AVON LAKE, OHIO—PRP CITY backwards in an impact. A recent article in the Lorain, Ohio from the local stations" adding that Federal Motor Vehicle Safety newspaper. The Journal , is devoted "it’s better if you have all the sta-

Standard (FMVSS) No. 201 as to the enrollment of the entire town tions in a town than one, because amended would require that instru- of Avon Lake's independent service people go to different stations.” ment panels, seat backs, sun visors stations into the PRP. Tony Abram, Phil Bruder, owner of PHIL’s and arm rests be designed to lessen an Avon Lake city councilman who SHELL in Avon Lake, pointed out that injuries when persons are thrown is also head of the city's safety com- "we see stuff far in advance of the against them in crashes. mittee is responsible for this develop- people driving the car and way be- FMVSS No. 203 as applied to light ment. fore the government gets wind of it". trucks and vans, would require steer- Councilman Abram read about the All of the station owners Abram con- ing assemblies to cushion the impact PRP in a Department of Transporta- tacted expressed a keen interest in which occurs when the driver strikes tion newsletter and decided the pro- the PRP, making Avon Lake the first the steering wheel in an accident. gram would be of value to the city in the U.S. to have all its stations FMVSS No. 204 limits the rear- community. He contacted the PRP involved in the program. those ward movement of the steering as- and we of course endorsed his idea Keep sembly to no more than five inches, wholeheartedly. Abram, when inter- parts and information coming, Avon when the vehicle crashes into a bar- viewed by the newspaper explained Lake. We hope this is the start of rier at 30 miles per hour. that “I got really good cooperation something big!

35 THE FORUM

One and a half million Ford Pintos of the bearings revealed that grease were recently recalled by the Ford was still evident; however, metallic Motor Co. to correct a problem in the flakes were apparent on the bearing fuel system design. The recall cam- surfaces. paign involves the installation of a The PRP would like to extend spe- Feldmann’s shop, AUTOMOTIVE gas cial thanks protective shield between the to Jim McCarty, Associate SAFETY SERVICE, INC., has also come tank and the differential unit. Four Editor of Brake and Front End Maga- across a 1976 Chrysler Cordoba recall being used, depend- zine, for his excellent article "kits" are on the which suffered a loss of steering ing the engine/exhaust config- PRP. The article, which in upon appeared power assist. The gearbox would uration of the vehicle. The type of the November issue, featured Harry allow turning with power only to the kit to be used depends upon whether May of May’s Auto Service in Mans- left. Upon examination, it was dis- the vehicle uses leaded or unleaded field, Ohio, discussing his participa- covered that the oil flow control valve gasoline and whether it is a single or tion in the PRP. May, a recipient of assembly trough was broken causing dual exhaust. the PRP Administrator’s Award stated all of the power steering fluid to flow FOX AUTOMOTIVE in Tulsa, Okla- “we've had no problems whatsoever, to the left side. AUTOMOTIVE homa, has reported a problem in the and NHTSA definitely has a good SAFETY SERVICE replaced this power recall service performed on a 1975 thing going. They make it so easy steering gearbox in V—6 Pinto equipped with dual ex- to help that we enjoy it’’. order to correct haust. Within three days of the in- the problem. The vehicle had only stallation of the shield, the shield 8,000 miles. began to melt, presumably due to the Gene Feldmann, President of the high temperatures of the exhaust sys- Florida Chapter of the Automotive tem. It is likely that the wrong kit Service Council, (ASC), has reported Tim’s Import of Hutchinson, Kansas, was used to repair this Pinto. Similar on an alleged front spindle defect in a regular PRP contributor, has sub- problems should nonetheless be re- a 1978 Dodge Custom 300 truck. mitted a total of 13 inputs involving ported to the PRP. In the meantime, The vehicle had approximately safety related defects this month. if you are involved in servicing Pintos, 1 2,200 miles on its odometer. After This is an unusually high count for a please take care to check the shield. inspection it was determined that the single contributor. Thank you Tim’s If you are installing the shields, re- outer end of the spindle snapped off " for your outstanding participation. member to double-check the part kit. 1 '/ 2 from the spindle tip. A check

THE SEARCH FOR THE ENGINE OF WOODY’S GARAGE, Montoursville, THE FUTURE Pennsylvania, reports a brake hose thing to start Secretary of Transportation, Brock and working together problem in the 1977 Dodge B-200 Adams, has asked the auto industry for the future,” Adams said. “The van. The brake hose can be to join in an all-out search for the recent years of trench warfare be- damaged by rubbing against the

engine of the future, calling for an tween government and industry over wheel, causing loss of brakes. One

automotive “summit conference” in fuel economy has resulted in a 1978 possible solution, according to the this car that gets miles Washington early year. about as many shop, is to re-route the brake line the fifty “Events in Iran and the announce- per gallon as did Model A and lengthen the brake hose.

ment of rationing by American oil years ago."

companies reinforce my belief that He said he will ask the Chief

the curtain is quickly dropping on the Executives of the Big Four to bring

age of the internal combustion engine the “best brains in the industry” to a TELEPHONE CALLS

as it is—and the fact is we have no meeting in Washington early in the Have you got what you need to

replacement,” Adams said in remarks year to press for development of a get us what we need? If you're out

prepared for the Economic Club of car that will again put America on of bags, if you’re out of tags or even

Detroit. top of world markets and eliminate if you simply want to get the message

“It’s time for industry and govern- the country’s growing dependence on to us fast—Give us a call COLLECT at ment to stop butting heads on every- foreign oil. (703) 527-4500.

36 parts return program s Mtts o*

S • [news U DEPARTMENT OF TRANSPORTATION NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4 No. 8-9 February-March 1979

FIAT UNDERCARRIAGE 1 5 SHOPS RECEIVE ADMINISTRATOR'S AWARD RUST RECALL Our PRP members supplied • Ise Automobile Service, North The U.S. Department of information last year that related Hollywood, California Transportation has announced an directly to 16 formal investigations. agreement in principle between Fiat • Kolesnik’s Service Station, Four of these investigations have Motors of North America and Rochester, New York already resulted in safety recall and NHTSA to recall 31,702 1970-71 remedy campaigns by manufac- • Las Vegas Wheel Alignment and model 850 Spyders because of turers. Over 850 parts were received Brake Service, Las Vegas, excessive undercarriage rust and from 193 shops during the past Nevada corrosion. This was in follow-up to program year. Of these 193 par- the NHTSA’s January 1979 initial • L.A.D. Auto Electric, Spokane, ticipants, 15 were selected to receive defect determination which included Washington the Certificate of Appreciation 1970-74 model 850 and 124 Fiat Award. • Foreign Auto Service Center, vehicles. Information concerning Minneapolis, Minnesota In making the awards, those 124 models not covered by the NHTSA Administrator, Joan Claybrook, • Big Brake present agreement is still requested. Safety Center, expressed her appreciation for the Gulfport, Mississippi Corrosion weakens critical areas voluntary effort put forth by these and components of the underbody • Woody’s Garage, Mon- shops in submitting components such as suspension and steering toursville, Pennsylvania and information on a regular basis. systems and floor pans beneath the The 15 shops to receive the award • Day-Nite Auto Station, seats. Failure of these components are: Kaukauna, Wisconsin can result in an accident. The photo A. shows the floor pan of a Fiat 124. • Ruth’s Garage, Colonie, New • Harry’s Auto Service, Great York The recall will require Fiat to Barrington, Massachusetts notify owners and repair the vehicle. • Automotive City Service Center, • Auto Brake Corporation, Where corrosion is so advanced it Nor- San Francisco, California cannot be folk, Virginia repaired, and the vehicle • Bob Chester’s Auto Service, was purchased after January 16, Arlington, texas 1971 (the Agencies eight year statute • Bud Jones Service, Delmar, New of limitation) Fiat will be required York to repurchase the vehicle. Member shops having informa- • Clemens Auto Repair, Racine, Wisconsin tion on those vehicles still under consideration are asked to forward it as soon as possible. Photo’s The PRP would like to extend a would be helpful. special “Thank You’’ to these shops for their outstanding work during the past year. We hope that you will Call us COLLECT at be joined by many others in making (703) 527-4500 your contribution to highway safety during the coming year.

37 THE FORUM

One and a half million Ford Pintos of the bearings revealed that grease were recently recalled by the Ford was still evident; however, metallic

Motor Co. to correct a problem in the flakes were apparent on the bearing fuel system design. The recall cam- surfaces. paign involves the installation of a The PRP would like to extend spe- Feldmann's shop, AUTOMOTIVE protective shield between the gas cial thanks to Jim McCarty, Associate SAFETY SERVICE, INC., has also come tank and the differential unit. Four Editor of Brake and Front End Maga- across a 1976 Chrysler Cordoba recall "kits" are being used, depend- zine, for his excellent article on the which suffered a loss of steering ing upon the engine/exhaust config- PRP. The article, which appeared in power assist. The gearbox would uration of the vehicle. The type of the November issue, featured Harry allow turning with power only to the kit to be used depends upon whether May of May’s Auto Service in Mans- left. Upon examination, it was dis- the vehicle uses leaded or unleaded field, Ohio, discussing his participa- covered that the oil flow control valve gasoline and whether it is a single or tion in the PRP. May, a recipient of assembly trough was broken causing dual exhaust. the PRP Administrator’s Award stated all of the power steering fluid to flow FOX AUTOMOTIVE in Tulsa, Okla- "we've had no problems whatsoever, to the left side. AUTOMOTIVE homa, has reported a problem in the and NHTSA definitely has a good SAFETY SERVICE replaced this power recall service performed on a 1975 thing going. They make it so easy steering gearbox in order to correct V-6 Pinto equipped with dual ex- to help that we enjoy it”. the haust. Within three days of the in- problem. The vehicle had only stallation of the shield, the shield 8,000 miles. began to melt, presumably due to the Gene Feldmann, President of the high temperatures of the exhaust sys- Florida Chapter of the Automotive tem. It is likely that the wrong kit Service Council, (ASC), has reported Tim's Import of Hutchinson, Kansas, was used to repair this Pinto. Similar on an alleged front spindle defect in a regular PRP contributor, has sub- problems should nonetheless be re- a 1978 Dodge Custom 300 truck. mitted a total of 13 inputs involving ported to the PRP. In the meantime, The vehicle had approximately safety related defects this month. if you are involved in servicing Pintos, 1 2,200 miles on its odometer. After This is an unusually high count for a please take care to check the shield. inspection it was determined that the single contributor. Thank you Tim's If you are installing the shields, re- outer end of the spindle snapped off " for your outstanding participation. member to double-check the part kit. 1 V2 from the spindle tip. A check

THE SEARCH FOR THE ENGINE OF WOODY'S GARAGE, Montoursville, THE FUTURE Pennsylvania, reports a brake hose

Secretary of Transportation, Brock thing and to start working together problem in the 1977 Dodge B—200 Adams, has asked the auto industry for the future,” Adams said. "The van. The brake hose can be to join in an all-out search for the recent years of trench warfare be- damaged by rubbing against the

engine of the future, calling for an tween government and industry over wheel, causing loss of brakes. One

automotive "summit conference" in fuel economy has resulted in a 1978 possible solution, according to the this car that gets miles Washington early year. about as many shop, is to re-route the brake line fifty "Events in Iran and the announce- per gallon as did the Model A and lengthen the brake hose.

ment of rationing by American oil years ago."

companies reinforce my belief that He said he will ask the Chief

the curtain is quickly diopping on the Executives of the Big Four to bring

age of the internal combustion engine the "best brains in the industry" to a TELEPHONE CALLS

as it is —and the fact is we have no meeting in Washington early in the Have you got what you need to

replacement," Adams said in remarks year to press for development of a get us what we need? If you're out

prepared for the Economic Club of car that will again put America on of bags, if you're out of tags or even

Detroit. top of world markets and eliminate if you simply want to get the message "It’s time for industry and govern- the country's growing dependence on to us fast—Give us a call COLLECT at ment to stop butting heads on every- foreign oil. (703) 527-4500.

3b WHAT WE'VE LEARNED FROM YOU

Recently, the PRP completed a Our initial contacts with new car

series of phone calls to all of our dealerships provided the PRP with new program members—parts sup- new members exhibiting a positive pliers, high mileage fleets and new attitude toward the goals of the pro- car dealerships. The purpose of this gram. In addition, dealership inputs contact was to establish an effective could provide the opportunity to line of communication with the new voice opinions and share expertise members on a one-to-one basis. with other PRP members. Up to this Through these conversations we point, however, few dealships have learned what our members expect of become actively involved in the the PRP as a source of information PRP.

John Shanahan of Washington Garage, for the service industry and as an Lack of active participation on Bergenfield, NJ, reports numerous incidents integral part of the highway safety the part of our member dealers of Ford vehicles with electronic ignitions ex- efforts. might suggest that they have periencing intermittent stalling. The problem nothing offer the PRP. don’t was reportedly due to failure of the ignition Although most of our parts sup- to We amplifier, shown above. NHTSA is currently pliers are unable to submit parts, believe this is the case. We are aware looking into this problem and any informa- they are capable of providing infor- of the dealer’s obligations to the tion you might have will be put to immediate manufacturer. We are also aware use. mation unique to their position as suppliers to both consumers and the that the dealer’s prime concern is professional mechanic. For this customer satisfaction— satisfaction reason, many of our parts suppliers through service and proper maintenance as well as feel strongly that the program is the good AMC SPARK valuable financial deal at the time of pur- ADVANCE UNITS in assessing potential problems in automotive com- chase. But a dealership today must The City of Lancaster Municipal ponents sold over the counter. be aware of potentially defective components on the vehicles it ser- Garage, Lancaster, Pennsylvania, High mileage fleet vehicles serve has responded to an article vices for its customers. Such an in the as an excellent means of monitoring November issue of the PRP News awareness can only serve to component failures in the short-run, dealing with potential problems in strengthen the customer’s faith in and most fleet administrators con- the vacuum advance units used in the dealership. The dealership is the tacted felt that the PRP was a American Motors vehicles. link between the consumer and the valuable trouble-shooting aid. The city of Lancaster has thirteen manufacturer there is no reason Fleets can be of considerable — AMC vehicles in its fleet. Five of that it should not also be a link in assistance in noting early indications these are 1975 Hornets equipped the defect investigation process. of a problem in a motor vehicle or with 258 cid engines. Of these thir- Honest, straight forward and teen vehicles, seven had spark component. accurate information is needed from advance units which have been the industry in order to maintain an recently replaced due to malfunc- tions. accurate reporting system. In turn, the information will be utilized in Lancaster’s motor vehicle bureau superintendent, Charles Simmons, our efforts to promote highway suggests that the problem may fuel mixture from the intake safety. The addition of parts sup- involve the quality of the diaphragm manifold into the distributor. Upon pliers, high mileage fleets, and new material being used in the manufac- restarting, the distributor cap can car dealers gives the program a new ture of the unit. As reported in the blow off due to the combustible vantage point for defect investiga- PRP News, a vacuum in the mixture. Continual occurrences of tion as well as a broader foundation distributor cap can be created when this situation can weaken the spring with which to build a realistic the engine is shut off, drawing an air clips holding the distributor cap. approach to automotive safety.

39 STEERING GEAR BOX PROBLEMS IN LIGHT TRUCKS AND VANS DEFECTS The PRP has recently been of the steering gear box mounting INVESTIGATION notified of three separate incidents holes. Belmont’s Garage of CHECKLIST of cracking in the frames of light Langhorne, Pennsylvania, reports trucks and vans at the point where that it was necessary to plate and • C9-01. Alleged Steering the steering box is mounted, weld the frame before remounting Gear Attaching Bolt Brake-O-Mst of Evanston, the steering gear box. The problem Failures on 1974-77 Ford Illinois reports that the steering box was noticed when the owner com- Vans and Light Trucks. plained of a shimmy resulting from in a 1977 B-300 Chrysler van used 9 C9-02. Alleged Structural bumps in the road. This is the by the LaSalle Ambulance Com- and Fuel Tank Corrosion in pany of Chicago broke away from second Chevrolet step van which the 1971-74 Ford Pantera shop has seen in the past six months. the frame, resulting in a reduction Vehicles, of steering ability. The van had Ford Motor Company recalled • C8-33. Alleged Stalling of 83,000 miles. 1976 E100, El 50, E250 and E350 1977 Oldsmobile, Buick and Similar problems in a 1976 Ford vans in 1976 for defective steering Pontiac Vehicles Equipped F-250 pickup truck were reported gear attachments. However, the with V-6 Engines. by Strahl’s Automotive of Canoga NHTSA is currently investigating Park, California. The shop reports • C8-29: 1973-1975 Pinto, related problems. (See the list of that the frame weld directly behind Mustang II and Bobcat current defect investigations in this Steering Coupling Flange. the steering gear box is cracked. issue of the PRP News). Any fur- Finally, a 1977 Chevrolet Series ther information on these problems • C8-27: Alleged Fuel 10 step van with 38,976 miles in light trucks and vans wou d be Leakage Problem in 1975 experienced frame cracking at three appreciated. and 1976 V-8 equipped Ford Granadas and Mercury Monarchs.

AMC SHIFT LINKAGE PROBLEMS • C8-26. Alleged Failure of Wiring Harness Connecting The State of Connecticut, Depart- broken bolt. The failure could result Rear Wheel Speed Sensor to ment of Administrative Services, in the gear selector lever indicating Anti-Lock Computer Fleet Operations, reports approx- park position but the transmission Module on Ford Series B, C, imately ten of its 1978 AMC Con- not actually being engaged in park. F, L, W and CL, 1975 to cords equipped with automatic The car, if parked on an incline, March 6, 1978. transmissions have experienced could conceivably roll if the parking C8-24: Alleged Failure of failures in the shift linkage bellcrank brake is not applied or does not • Certain 13 and 14 inch bolt. The fleet currently has 200 of hold. At least one of the vehicles Chrome Trailer Wheels these vehicle. involved had only 6,000 miles on it failure. Manufactured by Broad The bolt is located on the left side at the time of the The PRP Wheels Company. of the transmission housing connec- would be interested in the similar ting the manual shift lever to the occurrences in AMC vehicles. • C8-20: Alleged Malfunction bellcrank. The bellcrank is in turn of Power Steering Control connected to the gear selector lever Valve in 1975-1977 Ford linkage. Apparently, the forces GM Intermediates Granadas and Mercury involved can cause the bolt to break. Monarchs. Robert Sturm of the State of Con- The NHTSA is currently seeking • C8-02: Alleged Jumping In- information on front spindle or necticut Fleet Operations states that to Reverse from the “Park” bearing problems in late model GM the affected cars would not start in Position of Certain 1970-78 intermediate size vehicles. the park position and that there is a Ford, Lincoln and Mercury Also of interest loseness in the gear selector lever. are master Vehicles Equipped With C-6 cylinder, combination valve This loseness brought attention to and or FMX Transmissions. the linkage and ultumately to the caliper problems in these vehicles.

40 THE FORUM

The broken camshaft gear from a John Gross of Champion Parts Duncan’s Auto Repair, Phoenix, 1977 Ford Pinto was submitted to Rebuilders in Oakbrook, IL, reports Arizona, has submitted to the PRP the PRP from Maddox Auto Service a 1978 Mercury Marquis with an a torsion bar from a 1976 Dodge

in Atlanta, Georgia. The gear con- alleged problem in the choke Aspen that had broken. As seen in sists of a metal body with hard assembly. The welsh plug at the end the photo, the problem is similar to

plastic teeth bonded to it. As seen in of the choke piston chamber which one reported in the June 1978 issue the photo, the teeth broke free of seals the choke piston pulls out of of PRP News. On this particular the metal disc. The vehicle was in the housing, causing an excessively car, the torsion bar may have motion at the time of failure and rich mixture. The shop states that broken when the car hit a bump. required towing for repairs. The this rich mixture causes overheating. mileage at the time of failure was Champion also reports a throttle 45,000. valve problem in 1978 Marquis

vehicles which may affect all Ford vehicles with a c.i.d. greater than

460. The vehicle in question is equipped with a 460 c.i.d. engine with a four barrel Autolite carburetor. The throttle valves on the rear barrels can stick open when the

car is travelling approximately 30

mph, making it difficult to slow down the vehicle. Tim’s Import Sales and Service of Hutchinson, Kansas reports a In response to the October 1978 catalytic converter on a 1977 MG PRP News article on Jeep filler neck which continually overheats. The leakage, Winslow Foster of Hen- owner has tried 4 or 5 times to have niker Automotive, Henniker, New the problem corrected, with only Hampshire, reports the problem in temporary successes. After being his 1975 Wagoneer. After repeated repaired, the car will run for 2 or 3 attempts to fix by the dealer, the days. The engine then becomes dif- V & H Ford of Marshfield, tank was replaced. ficult to start, runs rough, and the Wisconsin, reports a possible design converter overheats. The excessive problem in the heater system of the Larry Jay of Blue Jay Standard, heat build-up from the converter 1979 Ford LTD as well as large Green Bay, Wisconsin, has called causes the floorboard to become engine Mercury vehicles. The new the PRP to report two 1978 Dodge uncomfortably hot. design of these systems is reportedly Aspen taxis he recently encountered susceptible to picking up snow and with brake failure at approximately ice which can accumulate on or near 45,000 miles. Apparently, the piston the heater core. As the core warms froze in the caliper, causing loss of

up, it melts the ice and in turn the braking action. A similar failure

fan blows the moist air on to the was featured in the June 1978 PRP

windshield. If the windshield is cold News. The NHTSA is currently MOVING to a bigger shop or a enough, a frost can form on the looking into caliper piston freeze-up better location? Let the PRP move inside surface, obstructing the in Aspens, Volares and some other with you. Call us collect when you driver’s view. This can happen, late model Chrysler products. Any have a change in address so you according to the service department, information you might have will be won’t miss an issue of the PRP within a matter of seconds. useful. News. (703) 527-4500

41 i

FORD TRUCK ENERGY AND FUEL ECONOMY I WHEEL STUDS PROBLEM The auto industry has been called OPEC’S pocket.” The trend on by Transportation Secretary towards the production and sales of Brock Adams “to cooperate with lighter, smaller, more fuel efficient The NHTSA has received reports the government in what must be a cars shows that the fuel economy of breakage of wheel lug studs on mutual effort to get on top of the program is working; and with 1975 and later model Ford pickup energy situation.” At a recent news transportation accounting for 55 trucks, in particular the F350 with briefing, Adams remarked, “the percent of the total U.S. consump- dual rear wheels. Failure of these costs involved in meeting the stand- tion of petroleum, automotive fuel studs could result in loss of vehicle ards are high, but those costs repre- economy becomes the country’s control. The NHTSA is currently sent an investment in the U.S. single most important energy-saving looking into this situation and economy. On the other hand, the program. 220 billion gallons of would like any information the PRP cost of not meeting the standards petroleum could be saved by 1990, members may have concerning Ford means dollars being spent for with motorists cutting their truck wheel lug studs. foreign fuel — and money in necessary fuel costs by $60 billion. Secretary Adams has scheduled a number of events focusing attention on the need for a more fuel efficient SPRING CLEANING and safe automobile. He called a two-day conference in Boston February 13 and 14 which was attended by 600 automotive technical experts. As a result of this seminar, Secretary Adams expressed confidence that a “kind of fun-

damental break-through” is possible for the automotive industry prior to the end of this century. He

also felt that the open meeting provided answers from both sides to “clearly indicate that we can achieve a subtantial improvement” in the average fleet fuel mileage. Representatives of both Chrysler Corporation and American Motors attending the conference expressed pleasure at what appeared to be an easing of the hostility between the automotive industry and the federal government agencies.

The fuel economy standards set for passenger cars are as follows:

Year Fuel Economy Standard 1979 19 miles per gallon 1980 20 miles per gallon 1981 22 miles per gallon 1982 24 miles per gallon Now where was that wheei bearing"?' 1983 26 miles per gallon 1984 27 miles per gallon 1985 27.5 miles per gallon

42 parts return program

U S DEPARTMENT OF TRANSPORTATION ® NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4 No. 10 April 1979

CHRYSLER BRAKE CORROSION THE GRADING SYSTEM Bud Jones Service, Delmar, New system for grading passenger York, reported a 1977 Dodge Aspen A car tires, the with front disc brake piston prob- developed by U.S. Department of Transportation will lems in the January PRP News. Mr. , begin 1979 tires Jones has informed us that the same April 1, for bias-ply and October 1979 for bias-belted vehicle was recently back in his shop 1, with brake piston problems on the tires. Radial tire grading will begin April 1980. The new uniform tire front wheel. An air chisel was re- 1, quality grading regulation is de- quired to free the piston from the caliper cylinder. The problem signed to help consumers buy the evidently stemmed from a malfunc- best tire for the money. Under the tioning dust boot that allowed regulation, issued last July, tires will moisture to enter the caliper be rated on expected treadwear, cylinder. GM INTERMEDIATE traction and temperature resistance.

The NHTSA is currently looking The NHTSA is continuing its The treadwear grade will specify into this problem, and has learned search for information concerning the relative tread life compared to that Chrysler used a glass filled ther- 1978-79 model General Motors in- other types of tires. Using a graded mosetting plastic compound called termediate size vehicles. Of interest numerical sequence as follows: 70, phenolic to construct the caliper are any front spindle or wheel bear- 80, 90, 100, 110, etc., the tires with piston. This should eliminate piston ing failures master cylinder, com- the highest number should give the corrosion, however it has been bination valve and brake caliper greatest mileage when driven under found that due to the tight fit of the problems. Any vehicles experiencing the same conditions. For example, a pistons, corrosion of the bore can trouble with more than one of the tire graded at 150 would be expected cause the piston to bind and freeze- above mentioned systems would be to have a tread life. ofJiQ^o jnore up. This can allegedly result in of special interest. miles than a tire graded at 100. brake drag, excessive heat, pad wear and reduced braking. The traction grades from highest These pistons are used in the to lowest are A, B, and C, represent- following vehicles: 1976 Dodge Dart ing the tire’s ability to stop on wet and Plymouth Valiant; 1976-1978 pavement. tire Dodge Aspens and Plymouth A graded A offers Volare; 1977-1978 Chrysler THANKS FOR PHOTOS the best traction, while one graded C will have less traction. Lebaron and Dodge Diplomat; 1978 We have been receiving more and Chrysler Cordoba and Dodge more photos and diagrams from our The temperature resistance grades Charger. members helping to explain par- are A, B, and C. The grade C cor- We would like to hear from our ticular problems submitted. We responds to a level of performance members concerning this problem would like to extend our thanks for which all passenger tires must meet and its effects. Keep your eyes open the extra time and effort taken to under a federal standard. Grades A for the models listed above and let supply us with this material and and B represent higher levels of per- us know what you discover. hope that you will keep it up! formance.

43 AUTOMATIC TRANSMISSION GEAR SELECTORS DEFECTS

The NHTSA has initiated an ad- • Are there any unique INVESTIGATION ditional inquiry into inadvertent characteristics which would CHECKLIST shifting into Reverse from Park on make it more likely for a Ford certain Ford vehicles. The agency operator to leave the selector in ® C9-10. Alleged Brake now has underway an engineering the intermediate position? Master Cylinder Failure on analysis into 1970-79 Borg-Warner 1974-76 Volkswagen Rab- C-4, C-3, and Jatco automatic 9 Do selector systems have a pro- pensity to toward Reverse bit, Dasher, Sciroco and transmissions, as well as the formal move rather than toward Park? Audi Fox. Defect Investigation on 1970-78, C6 Alleged and FMX. These 6 transmission • C9-02. Structural • Are there any additional cir- and Fuel Tank Corrosion in types cover the Ford lines since cumstances unique to Fords 1971-74 1970. Ford Pantera which govern the actual Vehicles. Field inspections of vehicles hav- transmission shift into Reverse? Steering ing experienced inadvertent shifting 9 C9-01. Alleged Gear Attaching Bolt revealed that many of the vehicle • Have you or your customers eyer Failures orf' 1974-77 Ford selector systems were in proper had any kind of car accidentally Vans and Light Trucks. operating order and when placed roll or drive away in Reverse? securely in Park, the vehicles would • C8-33. Alleged Stalling of not accidently shift into Reverse. In addition to the request for 1977 Oldsmobile, Buick and The incidents could be reproduced, help, we would like to remind our Pontiac Vehicles Equipped however, by intentionally placing shops that the automatic transmis- with V-6 Engines. the selectors in a position between sion gear selector, whether column • C8-29: 1973-1975 Pinto,

Park and Reverse. This could mounted or floor-mounted, is not Mustang II and Bobcat presumably be done in a moment of always a direct indication of the Steering Coupling Flange. inattention or preoccupation. The transmission valve body position. • C8-27: Alleged Fuel introduction of an external force to Misadjustment, mechanical Leakage Problem in 1975 the vehicle, such as a door slam, an deterioration or inaccurate selector and 1976 V-8 equipped Ford impact on the steering wheel, or a placement can allow for discrepan- Granadas and Mercury movement of the prop shaft, due to cies. Both transmissions shown in Monarchs. slight vehicle rolling, would the photos are in reverse. cause • C8-20: Alleged Malfunction the selector system and the transmis- Particular caution must be taken of Power Steering Control sion to shift to Reverse. while servicing a vehicle when: the Valve in 1975-1977 Ford We ask any shop which has infor- engine must be left running, using a Granadas and Mercury mation or experience bearing on any remote starter switch, trouble Monarchs. of the following shooting, neutral start etc. issues to let us switches, • C8-02: Alleged Jumping vehicle can travel know. A over 15 mph in Into Reverse from the “Park” Position of Certain 1970-78 Ford, Lincoln and Mercury Vehicles Equipped With C-6 or FMX Transmissions.

reverse at high idle. We urge our members to take the proper precau-

tions; make sure the transmission is completely into the gear you want, set the parking brake, turn the engine off (if possible) any time you exit, and chock the wheels.

44 THE FORUM Fourteen PRP shops have agreed to assist the NHTSA with a fuel hose study (see PRP News Feb/Mar Joyce Lyons of Scientific Prod- arm on each vehicle was cracked as 1979) over the next few months. ucts in Illinois, sent information seen in the photograph. The Fury Through the cooperation of shops, concerning tire failures on a 1977 had 29,781 miles on it and the like those listed below, the mission Chevrolet Impala Station wagon. Monaco had 65,965 miles. It is of highway safety is advanced. The tires are Uniroyal HR78xl5 unknown what caused the control steel belted radial white walls. A arm to break, as neither vehicle had Ed’s Automotive Center, Miami, noticeable shimmy developed at been put to any abuse out of the or- FL; Miami Auto Marine, Miami, Ft. Lauderdale, road speeds. Three tires were dinary. Pictured is the right lower FL; Wales Garage, discovered to have had tread separa- control arm from the 1977 Fury. FL; Auto Technical Associates, tion and one out of round. The 3 Inc., Hollywood, FL; Scottsdale with tread separation were replaced. Automotive Specialist, Scottsdale, One of these tires had also AZ; Alameda Foreign Car Garage, developed a slow leak. Las Cruces, NM; Frank Skinner Auto Instructor, Albuquerque, Tony Valinoti of Las Vegas Joe’s Service, Albuquer- Wheel Alignment and Brake Service NM; Auto que, NM; Nash Road Motors, New in Las Vegas, Nevada, submitted Bedford, MA; Bothel’s Garage, lower control arms from a 1977 Cape Elizabeth, ME; Paramount Plymouth Fury and 1974 Dodge Auto Center, N. Reading, MA; Royal Monaco. Both vehicles are Meade and Greenlee Garage, Salem, police cruisers. The cars were OR; Suburban Automotive, Lynn- brought into the shop to have a wood, WA; and Jack Daniels of routine front-end alignment. It was European Car Service, Arlington, then discovered that a lower control VA.

Thanks and a tip of the PRP hat. AUTOMOTIVE RUST WARRANTY CHALLENGE

Rusted out rocker panels may for perforations and 1 year or soon be covered under warranty if 24,000 miles against surface corro- U.S. auto makers heed the challenge sion. Future years will see these war- set forth by Transportation ranties extended. Both Secretary TELEPHONE CALLS Secretary Brock Adams and White Adams and Director Peterson stated If you need bags, tags or info House Consumer Affairs Director that although the Canadian stand- report forms call collect (703) Esther Peterson. They recently sent ard is voluntary, virtually all 527-4500. off letters to executive officers of 18 domestic and foreign automobile domestic and foreign automobile manufacturers have nonetheless in- companies asking them to provide cluded the principles of the Ca- American consumers with the same nadian rust code in their warranties THE PARTS RETURN rust warranty they give to Canadian to Canadian car owners. PROGRAM NEWSLETTER consumers. Canada has recently • Fiat Motors of North America, The Secretary of the U.S. Depart- adopted a rust protection code Inc., has recently recalled 31,702 ment of Transportation has deter- covering vehicles made in Canada, 1970 and 1971 model 850 Spiders as mined that the publication of this

as well as imports. reported in the Feb/Mar issue of the periodical is necessary in the trans-

On this side of the border, new PRP News. NHTSA is still in- action of the public business re- cars usually do not carry warranty terested in obtaining information on quired by law of this department. protection for corrosion of body other Fiat models prone to Use of funds for printing this parts and mechanical components. premature rust and/or corrosion. periodical has been approved by the Canadians purchasing new vehicles Any information, especially Director of the Office of Manage- will now be covered under a rust photographs, would be of interest. ment and Budget through March 31. warranty of 3 years or 74,000 miles Keep a lookout and let us know. 1982. r

parts return program J

U S DEPARTMENT OF TRANSPORTATION ® NATIONAL HIGHWAYnewsTRAFFIC SAFETY ADMINISTRATION

Vol. 4 No. 13 May 1979

RECALLS, INVESTIGATIONS AND DEFECT DETERMINATIONS

The NHTSA has recently an- and dislodgement which can result vehicles equipped with the L-4, 151 nounced an investigation into VW in fuel leakage, fires, injuries, CID engine. The design of the front master cylinders, an initial defect deaths and property damage. The suspension of these cars can allow determination involving fuel tanks NHTSA has received reports of at the engine mount bracket to become in Ford Mavericks and Comets and least 26 rear impact collisions with deformed if the suspension bottoms a recall campaign of Chevrolet fuel spillage and fires, resulting in at out. Due to this deformation, the Monzas, Pontiac Sunbirds and least 31 fatalities and 19 injuries to bracket will make contact with the Oldsmobile Starfires voluntarily vehicle occupants. steering linkage which, in time, can undertaken by General Motors for result in difficulty returning the engine mount problems in certain of GM ENGINE MOUNTS steering wheel to a straight ahead

their 151 CID equipped vehicles. General Motors is voluntarily position after a sharp turn is made. recalling 172,000 of its 1977 and The NHTSA has had no reports of VW MASTER CYLINDERS 1978 Chevrolet Monza, Pontiac accidents or injuries, in connection Sunbird and Oldsmobile Starfire with this problem. Master cylinders in 1975-76 VW Rabbits and Sciroccos and 1974-76 Audi Foxes and VW Dashers are currently being investigated by the

NHTSA. The NHTSA is looking into the possibililty that a faulty seal in the master cylinders is causing a reduction in stopping ability. Thus far, the NHTSA has received 30 owner complaints, including two reported accidents and one injury. Further information on this potential problem, as discussed in the PRP News, November-December, 1978, would be most helpful. Please forward any problem master cylinder without first disassembling it.

FORD FUEL TANK The above photo shows a 1977 bolts and welding to the frame. As An initial defect determination Dodge B300 Van with 52,000 miles seen in the photo the crack has has been announced by the NHTSA experiencing cracking of the frame. grown considerably. This fleet has regarding fuel tanks in 1970-1973 The information and photo was also had several 1978 models with Ford Mavericks and 1971-1973 submitted by the City of Phoenix in 12-15,000 miles experience similar Mercury Comets. The fuel tanks of Phoenix, Arizona. The problem cracking. Reports of a similar these vehicles are, according to the started as a small crack where the problem were noted in the PRP NHTSA, subject to failure, rupture steering gear box is attached by News of February-March, 1979.

46 , SAFETY A FUTURE FOR DEFECTS The NHTSA, with the help of panel that would enable the driver INVESTIGATION Minicars, Inc., of Goleta, Califor- to monitor operating systems in the CHECKLIST nia, has designed a prototype vehicle, and a radar braking system • C9-11. Alleged fuel tank research safety vehicle that will pro- which would signal if the driver is failure 1970-73 Ford vide protection in 45 to 50 miles per following the vehicle in front too Mavericks and 1971-73 without serious closely and would automatically ac- hour frontal crashes Mercury Comets. the driver and front tivate the braking system if a high injury to 9 C9-10. Alleged Brake passenger, eliminate 75 Vo of the speed crash is unavoidable. Master Cylinder Failure on serious injuries and fatalities from 1974-76 Volkswagen Rab- significantly side impact crashes and bit, Dasher, Scirroco and reduce the impact forces on a Audi Fox. pedestrian. The four passenger car • C9-02. Alleged Structural is also fuel efficient, has low exhaust and Fuel Tank Corrosion in emissions and is easy and inexpen- 1971-74 Ford Pantera sive to repair. Vehicles. Some future safety-related addi- • C9-01. Alleged Steering tions to the vehicle include an anti- Gear Attaching Bolt on 1974-77 Ford Vans and skid braking system that would Light Trucks. reduce stopping distances, an elec- C8-33. Alleged Stalling of tronic display built into the dash 9 1977 Oldsmobile, Buick and Pontiac Vehicles Equipped RUST REPORTS with V-6 Engines. © C8-29. 1973-1975 Pinto, Rusted out rocker panels may problems primarily in the vehicle’s Mustang II and Bobcat soon be covered under a warranty as undercarriage and frame. Steering Coupling Flange. reported in the April 1979 issue of The information, supported with 9 C8-27. Alleged Fuel the PRP News. Since that time the photographs, clearly shows the Leakage Problem in 1975 PRP has received numerous reports problem. The vehicles involved were and 1976 V-8 equipped Ford of corrosion problems in various one 1971 International truck, two Granadas and Mercury domestic vehicles by PRP members. 1972 Mercurys, a 1968 and 1975 Monarchs. Eagle Transmission in Elmira, Chevrolet, a 1970 Duster and a 1968 • C8-20. Alleged Malfunction N.Y. reported a 1973 Dodge Polara Pontiac. Pictured is the rusted of Power Steering Control with 72,000 miles where the main frame from one of the 1972 Mercury Valve in 1975-1977 Ford front supports on both sides of the vehicles. Granadas and Mercury vehicle rusted out. The rust was Monarchs. discovered when the vehicle was on a lift during a transmission inspection. THE PARTS RETURN Katon’s Garage in Spearfish, SD PROGRAM NEWSLETTER reported that they have seen several The Secretary of the U.S. Depart- GMC vehicles with serious or severe ment of Transportation has deter- rust problems. The shop has seen as mined that the publication of this much as 20-30% of various vehicles periodical is necessary in the rusted out including components transaction of the public buiness re- such as door panels body, and quired by law of this department. rocker panels. Use of funds for printing this John’s Body Shop in Bingham- TELEPHONE CALLS periodical has been approved by the ton, NY reported seven vehicles If you need mailbags, tags or info Director of the Office of Manage- from various domestic manufac- report forms, give us a COLLECT ment and Budget through March 31 turers all experiencing severe rust CALL (703) 527-4500. 1982.

47 The State of Wisconsin’s Depart- THE ment of Transportation reports a FORUM broken hose from a 1977 Plymouth Volare with approximately 58,000 As shown in the picture, the V & H Ford, Inc., of Marshfield, miles. The fleet states that the outer Village of West Milwaukee, Wis. Wis., submitted information to the rubber protective covering broke at reports a mis-aligned exhaust system PRP concerning a new style wheel the metal fitting, causing leaking tailpipe on a 1977 Plymouth Fury used on 1978-1979 Ford 9000 and loss of front brakes on the Coupe with 36,712 miles. The align- trucks. This new style wheel, part vehicle. ment allowed gases to accumulate number D7HZ1109C, replaces the on the inside of the rear bumper. old style part number C97ZH09K Reportedly, the resulting heat was and according to this dealership is In response to articles in the intense enough to melt the plastic lighter and less durable. These February-March 1979 and back-up lamp lens and cage. In wheels are used primarily on trucks November-December 1978 issues of addition, Lt. Springer of West for off road use and allegedly can’t the PRP News, Auto Brake Corp., Milwaukee reports that the gasoline withstand the stress as they are in Norfolk, Va. reports similar tank filler pipe is less than 12 inches reportedly breaking at the flange. occurrences of AMC electronic from the melted lens, creating a ignition problems. A dieseling potential fire hazard. engine (with the ignition off) could The State of Georgia, Georgia cause gases to enter the distributor State Motor Pool, submitted infor- blow the cap off making restar- and mation on a 1978 Nova with 78,000 ting of the vehicle impossible. The miles. The Nova is equipped with a shop also stated that an excessively 250 cu. in. 6 cylinder engine and rich mixture could cause backfiring. power brakes. The vacuum line from the intake manifold to the

Gil’s Safety Service in power booster became clogged with Ridgewood, N.J. has seen many carbon causing a loss of power assist Volares and Aspens with brake to the brakes. The fleet has also seen problems similar to those described similar problems in 2 or 3 other in the January 1979 issue of the vehicles. PRP News. Gil’s reports a 1977 Dodge Aspen with approximately 24,000 miles in which the brake Congratulations to Midway piston froze in the caliper. Chevrolet, St. Paul, Minn., and

Also reported by Gil’s were Ed Coffer of ATS in San Diego, Carol Buick, Evanston, 111., on breakages of the pivot bar support has reported problems with the receiving the Time Magazine Qual- plates in 1976-1978 Volares and automatic transmission selector ity Dealer Awards for 1979. Both Aspens. According to the shop, the levers in late model Jaguars. The PRP members were honored for ex- pivot bar supports plates could shop has seen several Jaguar XJ6’s, ceptional performance in their break due to fatigue or failure when model years 1974-78, equipped with dealerships combined with exposed to heavy stress. Chrysler Borg-Warner transmissions that distinguished community service. A recalled over one million 1976-78 have experienced the gear selector tip of the PRP hat to Midway Volares and Aspens in 1978 to lever moving from park to reverse Chevrolet and Carol Buick. correct this problem. If you are while the engine is running. aware of similar breakage of pivot Apparently the problem is with the bar support plates in these vehicles, selector lever that is mounted on the Thanks to Scotty’s Auto Repair, please try to determine if the owner transmission housing. Through use, King of Prussia, Pa. and Anderson received a recall notice, and whether this lever enlongates and becomes & Buckner, Arlington, Va. for the owner took the car in for correc- loose. Allegedly, this looseness can assisting an NHTSA safety defects tion and forward all information to allow the transmission to shift, by engineer in his inspection of the PRP. itself, from park to reverse. Volkswagen accelerator cables.

48 r parts return program J U S DEPARTMENT OF TRANSPORTATION • NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

Vol. 4 No. 12 June 1979

DEFECT INVESTIGATION INTO UNIROYAL “TEMPORARY USE” STEEL RADIAL TIRES SPARE TIRE WARNING The U.S. Department of had developed tread separation and The NHTSA has received reports Transportation has announced a bulges in the sidewalls. that some motorists are replacing safety-related defect investigation If you have any information on the T-type spare tire with a conven- involving some Uniroyal steel-belted the Uniroyal tires involved in this tial, full sized tire, while still using radial tires. tires under The investigation, or have seen problems the special, narrow, T-type rim investigation are the larger sized with other steel-belted radial tires, designed only for use with the tires in the PR6 line including HR78 contact the PRP. smaller spare tire. This can be an larger, those with and and JR LR extremely dangerous practice, since size designations, which are such a mismatch between tire and normally used on full size cars and MILLIONS STILL DRIVING rim can result in separation of the station wagons, and all sizes in the DEFECTIVE FIRESTONE TIRES tire from the rim and possible loss PR5 line made in 1975 and 1976. of vehicle control. The T-type tire Although the National Highway According to the NHTSA mil- and its specially designed rim are Traffic Safety Administration lions of motorists are still driving on narrower than other tires and rims believes the problem is more the defective Firestone 500 steel supplied on the vehicle. prevalent in the larger sized tires in belted radial (SBR) tires that are in- the PR6 line, it is also looking into volved in the massive recall that failures in the smaller sized PR6 began last November. Only about tires. Most of these tires were fifteen percent of the tires have been original equipment on new General replaced through March 31, 1979. Motors vehicles, while a smaller Firestone has exchanged only 1.6 number were installed on new Ford million out of a potential 8.7 million vehicles. They were also sold as tires which qualify for free replace- replacement tires. ment. They have replaced an

The NHTSA is aware of at least estimated 500,000 tires out of a 30 accidents involving 10 injuries potential 5.3 million tires eligible to that are allegedly the result of be exchanged at half price, which failures in the tires. Also, Uniroyal were sold prior to September 1, reports receiving 538 complaints in 1975. The T-type tire should be used 1978 alleging blowouts or other The major recall is purpose of the only until the conventional tire can potentially hazardous failures on to get the defective tires off the be repaired or replaced, should not PR5 and PR6 tires manufactured road. NHTSA has urged Firestone be driven at high speeds, nor should since 1975. to step up the pace of its notification it be rotated with the other tires on efforts. The PRP has received several the vehicle. If the T-type tire must reports concerning problems with Essentially the recall covers all 7 be replaced, it should be replaced the larger sized Uniroyal steel-belted rib 500 SBR tires sold after only with a tire designed to be used radial tires from Scientific Products September 1, 1975 and manufac- with the special rim. Full-sized tires in McGaw Park, Illinois. In a tured prior to Jan 1, 1977. Included must not be mounted on the special related incident, the State of are tires of similar construction rim and vice versa. Please remind Georgia reported failures involving made by Firestone for sale under your customers of the correct pro- Goodyear Polysteel radials which other brand names. cedure for using these tires.

49 —

FEDERAL MOTOR VEHICLE SAFETY STANDARDS GASOLINE TRANSPORTATION Since the aim of the PRP is to • FMVSS 104—Windshield Wip- HAZARDS promote highway safety, we feel ing and Washing Systems that member shops should be aware Specifies the passenger car wind- At a time when the fuel crisis is of the federal motor vehicle safety shield area to be wiped and mounting, the U.S. Department of standards that exist. In September requires washers and high per- Transportation has issued a warning 1966, the National Traffic and formance, two or more speed to motorists on the hazards of Motor Safety Act was signed into power-driven wiping systems for transporting gasoline in containers law directing the Secretary of passenger cars, multipurpose in the trunk of a car. According to Transportation to issue Federal passenger vehicles, trucks and NHTSA Administrator Joan Motor Vehicle Safety Standards buses. Claybrook, “people are traveling (FMVSS) to which manufacturers with lethal liquid bombs in the of motor vehicles sold in the United 4 FMVSS 105 — Hydraulic

their cars . . . Even a States must conform. In this and Brakes— Requires passenger cars trunks of subsequent issues a brief description and school buses utilizing minor rear-end collision or a spark of each standard will be presented. hydraulic brakes to have a split from a short in a tail light or brake brake system incorporating ser- light could set off an inferno • FMVSS 101 — Control Location, vice and emergency features that resulting in injury or death.” Identification and Illumina- are capable of stopping the vehi- tion — Requires that essential One gallon of gasoline has the ex- cle under certain specified condi- controls on passenger cars, plosive power of fourteen sticks of tions, a parking brake system multipurpose passenger vehicles, dynamite, and motorists are capable of holding light vehicles trucks and buses be within reach strongly urged to avoid carrying or on a 30 percent grade and heavy of the driver restrained by a lap storing fuel in portable containers in vehicles on a 20 percent grade, belt and upper torso restraint, their cars. Fuel should only be and a warning light system to and that certain controls be iden- transported in extreme emergencies. indicate loss of pressure, an- tified and illuminated on the In such instances, the container tilock system failure and parking instrument panel. brake application. should be durable, securely closed, but vented, and protected against • FMVSS 102— T ransmission accidental spillage or damage. Shift Lever Sequence, Starter • FMVSS 106— Brake Hoses— asked re- Interlock, and Transmission Establishes requirements for PRP members are to hydraulic, air and brake motorists of this potential Braking Effect— Requires that vacuum mind transmission shift lever se- hoses, brake hose assemblies, safety hazard. quences on passenger cars, and brake hose fittings for multipurpose passenger vehicles, trucks, buses, trailers, motorcycles equipment. trucks and buses have the and conditions of reduced visibility neutral position placed between for passenger cars, multipurpose forward and reverse positions. • FMVSS 107— Reflecting Sur- passenger vehicles, trucks, Requires an interlock to prevent faces— Requires that passenger trailers, buses and motorcycles. starting the vehicle in reverse cars, multipurpose passenger Included in the requirements are and forward drive positions. An vehicles, trucks and buses come side marker lights and reflectors, engine-braking effect in one of equipped with matte-surfaced hazard warning and backup the lower gears at vehicle speeds windshield wiper arms, inside lights and replacement equip-

below 25 miles per hour is also windshield moldings, horn rings, ment. required by the standard. and frames and brackets of inside rearview mirrors. • FMVSS 109—New Pneumatic • FMVSS 103 — Windshield Tires — For passenger cars, Defrosting and Defogging • FMVSS 108— Lamps, Reflective specifies tire dimensions and Systems— Requires that pas- Devices, and Associated laboratory test requirements for senger cars, multipurpose Equipment — Specifies re- bead unseating resistance; passenger vehicles, trucks and quirements for lamps, reflective strength, endurance, and high- buses be equipped with wind- devices, and associated equip- speed performance; defines tire shield defrosters and defogging ment for signaling and safe load rating; and specifies label- systems. operation in darkness and other ing requirements.

50 THE FORUM

Joyce Lyons of Scientific Prod- Gotham Auto Lease of New Tony Valinoti of Las Vegas ucts, McGaw Park, Illinois has Rochelle, New York also submitted Wheel Alignment and Brake Service reported a 1978 Oldsmobile Cutlass three ignition amplifiers. These were submitted to the PRP a pair of

Supreme in its fleet with worn rear all from 1977 Lincoln Continentals McPherson Strut cartridges from brake lines. The worn lines were with mileages ranging from 15,000 the front suspension of a 1975 VW discovered during replacement of to 20,000. Each car experienced sud- Super Beetle Convertible with the snow tires. The brake lines were den stalling. Only one was able to be 16,662 miles. Both cartridges would showing signs of wear apparently restarted. The Fleet has not noticed not collapse causing a very stiff ride due to rubbing on the car’s frame. an increase in the problem in the and could reportedly result in han- The problem was discovered before warmer weather. dling difficulties and excessive strain the lines were worn to the point on front suspension components. where they could leak brake fluid and cause a loss of braking. Also, the base plate of the original equip- Wales Garage of Ft. Lauderdale, ment jack broke when it was being Florida called the PRP to report a used to change the tires on the same broken right motor mount on a 1977 vehicle. The car had 35,000 miles. Volvo 242 with 30,000 miles. The mount which appears to be aluminum, cracked into two pieces and could not hold the engine in place properly. Misalignment of the V & H Ford of Marshfield, engine/ transmission reportedly Wisconsin submitted to the PRP cause difficult shifting. The shop two electronic ignition amplifiers. also reported a difficulty in obtain- The amplifiers were from a 1979 ing the replacement part. Being Lincoln with 308 miles and a 1978 unable to find the part in stock at Mercury with 16,000 miles. In both any parts supplier, it had to be of these vehicles the engine would ordered from Volvo taking approx- die out without any warning. The imately five weeks for delivery. The dealership also noted that the occur- same problem has been seen on TELEPHONE CALLS rence is more prevalent in warmer other vehicles. Let the PRP know if If you need mailbags, tags or info weather, however it could happen at you run across any broken Volvo report forms, give us a COLLECT any time. engine mounts. CALL (703) 527-4500.

Julian Green of the State of Paul Lovely of Paul’s Garage in THE PARTS RETURN Georgia, Atlanta, Georgia reports Dayton, Ohio submitted to the PRP PROGRAM NEWSLETTER two 1977 Plymouth Volares in its a broken camshaft gear from a 1974 The Secretary of the U.S. Depart- fleet which needed the front brake Ford Mustang II with a V-6 engine ment of Transportation has deter- lines replaced. The brake lines are and 28,000 miles. The problem is mined that the publication of this routed directly under the battery similar to that reported in the periodical is necessary in the trans- making them susceptible to corro- February-March 1979 PRP News. action of the public business re- sion from leaking battery acid. The plastic teeth bonded to the quired by law of this department. Chrysler has recalled many of these metal body of the gear broke free. Use of funds for printing this vehicles to install a protection shield The broken camshaft gear stopped periodical has been approved by the over the brake lines to guard them operation of the engine. The car had Dirctor of the Office of Manage- against the corrosive action of the to be towed to the service garage for ment and Budget through March 31, battery acid. replacement of the gear. 1982.

51 —« t • » — , — « j j .

a cc X a rv — — cc o c rv c x w~ © tt g o c g o c o CL X rv a •— LT s •» o 55518118 c a c ir c C X c X I 2 rv X a c lT IT co z if x rv x X x. P^ ST fX. z X Hw a f— X . g c C c g c - 0 c c. a a >- o X • C _) c c X e c X c •— x < o o a X c x c. c. e c X

Pvi X <1

X _ x CL 3 C a a co • CT X r~ z 57 * 7 < 3 r- » r- C u_ ct. rv X J" S' *— T c u. X — a UL_ X G tr X ir o X 1 »— i3 <7 • 2 > < a > L_ f| a <— X C X I X ^ X 3 H z. 3 X c X X a 3 X vr u_ F— > w z z _ X 3 . X z • < «x x T • a CO *- 3 X 2 X a 3 3 3 a X X 3 LT > 2 Z Rivr, to 3 <1 CO .. X z 3 •< — F— I »— CO »— X X 3 (O > 3 3 a c. > X F 2Z X Z < z co CO C X a > 3 OHSF £_ aj 3 z a • z x < X ru 2 < a 3 3 3 f— X X. 3 r X CO u CO -- X X LJ CT I . r~ z 3 X X X X OJ o C. c a o © «J X CO o tr- 2 C C a < CC r^ o »-H o 2 o • c a © <3 G x C c 3 LUBF < c: X c a c 0 LT X X G a L_ — c ('O00 — x o X o IT G X G Z 2 G a G X <. c G

; FunCRAM X > t Cl X CO X c X X of to -J 3 Cl LS X. > a 2 3 X c u_ "5 Q 3 Z < <1 3- ~~C X X c. _J X a 3 Z x 2L X > X w r- £j IACK • z. > X X 3 3 a Cj X z <~~

CO . co 3 z a 3 X X 3 3 < 3 1 Ct > 3 X • 1 c < X a co 3 a 3 2 Z BFTIIPN — *— x 3 CO x » 3 O X X X X • a X 3 Til 3 a. CL Xl Ct X X C. X X 3 Z X Z X e> X X nn0,EN0 LlJ LJ X <3 c c z —1 X CO X' X X X CO z 3 a. a. a. CO x< z L_ X <3 3 <1 3 a <1 a X C C X 0IJF La_ a O CL >- CO X 3 3 X X I Z X X X a 3 Zj > % 3 % CO * o a 1 3 <1 c CO 3 3 a CO 3 PACTS CO : 'sp - X o X X X a X Z X X X 3 2 ‘X F a. *— 3 u.> C z z :> X iC co 3 CO < X < LS < CO > X a (O T *— *— • 3 Ct 7. Zl CO 3 Jt X , it > co X 1 X 1 X -AJ Q- x Z a. i±j CT X a CO X X co X X X (_) < a U X a CO 3 • CO <1 X o a X’ c • X < a X < w < 3 oi 3 X C X . A— *— OF fUPR*OBILF *— z .-L X 5 X X 3 z a x c a a LT a U-- 3 X _ r~ b. z - CO X X CO 3 X a 3 c X C A Rfin X UJ lj Z o X X UJ a > X a X a a. X a X X 3 it c a NK 3 Z -a u_ X r X X 3 •«a c 2 X X it z a X CO a C a C X (X 3 tr z z _ X I TIf 2 Z — O X G. X — X a po a a ru X •-> 3 •O 2 rt X c •< o o LD c G X 3 G co XI (X G Z o c w X o a 3 G r • cc X z X c ZJ 000004 u z z _J Z X z z Z Z z z z Z a 3 (IN 2 c 3 .i C' X X o C i G 2 z X G a X G x» X hH c X G 3 Z 3 o 3 0: 3 X a CL c G> tt G X a G a£> a in x a a © a a G 3 ion STFERT'JG DC Z o • t- z X UJ UJ c • X © X X © it X X X X o X X © a X >- CO a: Z it X X CO X (X X X X X 3 X X X < X ("FAR r z c c 3 z c X X X • X IP 3 z X < x G < Z X r- 3 x oc X’ C 78 mm t— 3 o > X) 3 CO CO a CO r- X X CO r- a CO G a < CO r- X to r- 2 2 Z X © © © © © © © © z CO G G © G © o © ©

~~C CO G G © © G G G © 580000 a~~

~~Cl X SC X oo x vC c >0 X 1 X > rv C x G © rv © © X X r- r- r- r*- 1^ r-~~

~~X. o~~

~~Z a a a a a CL a a P~~

~~a X r- aO CO z aj rv pn PO *-« 2 © © © a 3 © o © z in in in 52 i - • - *1 „ r - • • <~~

P a a X X x> X X X X a cr — c pj p. X <\, X — o o •— •— o o o cr a. c. — Pj c X e c «— o a X cr cr — c w- «- c «- X »- r\j _ X p- c IT — iT X X rv. X Z p X 0 J~ a c a c o c c X c* c c c P c. -L. o X

~~c c c: o c c o c — o o o — c c o o c. c < cr c o X C" c o X X a c •— r IT c o o — X c X 55 c c c rv. o - c. o cr o c. cr~~

~~< <3 c.; 3 3 3 3 3 I 3' • • U. X 3 a 3 C »— IT Z p. X «/> i <5 d z *— • O C 5T o c. a c~~

u i/. : a_ U. z < • z a. X Z tr c l: — d d co z _ w 3 3 C *— c z a —j Q 3 t/. X a- X X X to of 3 »- X • d d c X 1 X t— 3 a. a> r> u. z d cr X z - 2 x z < < »— 3 a 3C c- Z »— X z e • C cr c 0 3 O if co- Z O c *- >- co- MWOr-PAM 3 X c U- Ll X . - d* PFTIJPN 3 . 3 UJ •<3 a> JO X O d r 3 a. z X X 3 iL *- X 3 3 a lu U CC X X X 1 3 3 a. a f**- < — c c > CO CO CO UJ x ls > Z X r— CL X X »- e c > —> 7 X X c. d d d *— 10 t— »— • PAPTS co _ c CO Zi 3 3 — X X 3! c r- if CO d 3 d 'Sil-jH — L Z

U_ Cl — z ti- X < s r 1 a 3 1 — 3 I *— 3 er LJ 1 d z r~ d CO 3 < <1 (J T* a. X 3 'C 3 X X 3 X z X HuwSu ii z *~ cj a • > h- 3 U»' > X c. X 3 a *—> U-> / ur f- U.' UJ a^ X Z 3 a z 3 Z Vd Z < c a -L T *— 3 I I X 1 3 a-< CO a *— C 3 c a • 3 < X 3 3 UJ __j Jl. > 3 3 1u -fd a. 3 3 a X *- 3 *— 3 p z rvj c. ro •— a. r^. Z Z vT a C 3 c* c < O lL z 0 X c 3 c 3 CO X c X c o 3 our/000 -IS'-N 3 r X Q *— rj 3 55 3 55 3 rp 3 5 55 55 3 C • c a CO C CO O CO O d 0 Z C- >0 c 1 3 h* u pj f\J Pi PI PJ pj Pj rsj c 0 O 0 c 0 c c o LL. a CO — _ 3 > pj nj 0 — PJ PJ c pj K *— X >0 r- r- K o» <1 UJ 0 0 0 c* 0 0 C O o 3 X CO X X X X ac x UJ r- r^ r*- 3 a:

~~.*-< o <1 < X~~

~~Or IP co >c cr rP ro PI Q. Ui M rvj X 0 X X O cC cr x a a X X 0 O a a x a 53 iP IP IP a a X X 0 C. x o a a X a X a X X~~

~~Z X o c *— X o o X 3 o o z c o 53 ' 1( • j^A «A 1 JA - A1»J 4 »«*. 4J 1 1» -1 A~~

~~X c >c o c o cc K' rvj c o — c c fr*. 33 a o o c o c e — •-* a a. o o c r- c cr «— or~~

~~r ci v- c e c e c c — nsS8n?nr>h i z c «- a - O _a_- . w _J c.~~

~~< i a. c c. C- ir c. o Q *— *- c — *- r\j Kt rv o X fr- c o o c c C o <1 C 2 N~~

~~(X r~~

Mil c. 2 a~ c. LA. W U. z a_ c_ a CO X A— <1 • A— 7 jj a LA. Q > c/3 C/j a o_ T c. Li. a. c x fr- 5 A-HSF X Zj -J a. LI a ee 0 z A— r c *— <3 »- cr ' c 2 _ 2 0. 3t X, _ X a.- x • 0 <3 ptvtm"- c CO A— •*1 X w T a_ c > A— CO a a X X z IIMTII A— A— , UJ rr a c u. A— 21 X •t. X a 7 WI_ i z X- > c; • <3 x •— a CO 0 *- a. a • (Z CO A— c <3 A— 0 z m«o 7 r <3 co cr X X c c. LI <3 c c. X A— X 5 < C.- r- x co z cr t— S c s — X' a a A— X c a c- c- A^ rvj x a cr X < X cr UJ o a c. • C. c a 0 A— cr. c • LJ 0 LJ r oooo LI r-- <: c. z nj V • UJ X it — > 1 rA Up A— re A— I A— < co ppnnRAM > r i/ i c- a. -j c a 0 c c a C a S I

>- f-XCASSTVF A— c a a a x 1 a ~ 1 X i a a x. a X' CO c A— A| >- A- A— fr- r u_ — a Lap CJ* CO cr > X a_ - z <3 • c x 1 UJ a. 1 w— A— CO cr a. x LkJ z CO a X - - c X c CO LJ A— a z a K a NHn-MF LkJ a_ c c hL. w x X Z x Mi cr. > X > O • X a > _ a fr- c c 1 pf-tmpm A— cr. A— a- A— A— a. ZZ ee , CO X C- a x . I A— •S Up u. 1 cr 3 CO A— 3. h— A— » a IIS «u LJ X c _J A— a co > Cj A— a_ a Z X Up > c u. u_ r— o z A— CO c. CO UJ > • x X CO A— C A S-HfiSf A— r- A— >- u_ a 3 z > _ _ ; CO _J -J z — .j x c nN C C > a u_- CO j __ > x > CO > c c > z >- CO »- x i papTS X *- a o CO • LJ a u •« 0 a u A— a- LJ A— x. 9 z u s »a*, fr- A— . — Lk.' CO CO u. z. aa x. < . a z CO c > z. UJ i X a X' cr C^ <1 a x a -j 1 a u. A— a A— x a A-* UJ 3 c Nf- v <3 c a a_ A— a. a u. -i fr- X x A— A— >- A- LT> •< fr- > x fr- Cl Ci z a X u. a •-h 2 »Xj -J < c z U_ A— ee A— <-/ co- ex X X < a ee A— CO ee -J A—. A— I t MISalIGN-El) a a c — a J UJ a X X X z X 1 X c. X z x _ Li- n *- A— a 8 C <3 1 c_. a • 7 a g co a 1 CO t x 0 Up X IC-L a. Zc. A— > s B- LJ LJ CL LJ X UP LJ CO UJ 0 * a- Up A— UJ LJ CO LJ e. <

*— . • A— A— A— A— A—* U LaJ L_ a. 2 > C • Cl 0 C it A- 0 a a Hiwn

<1 r—i • 1 <1 X z X CO -I CO _ -i Z —» -J z w z -J x < ; c —. x X »— A— ~ c. a. LJ H- cr -J c_3 X' a A— —P w > A— X •<5 a X UJ 3 c MJl a i UJ <3 *— it < _J A— < -J c < X <1 a <. >- f- — >- cy — =7 2 ; Z UJ a fV w < a a > a > a 'V a n z HOSF Q < c x cr c C. a a 0 LJ c O u 0 0 LJ x 0 : x c — CJ c x 1 £*• >- . r\j >- >- X cy ro X > » > ^ m wT -J > 3? a > PJ V0» 000501 c 2T X 0 . x 0 a c X 0 a 1 0 a X O <1 X C x X 0 a H CO o LA- o • 0 > a • 0 UJ X • 0 UJ • ^ Up • ^ • >0 a • c a Up o X < CO c <3 UJ CO 0 fr- CO 0 fr- co fr- CO «•* fr- co — CO 0 »— S, • A— ee ee CO ee RPAKfe > a it: ~3 * CL * a 3C it a z a »-A a a 0 uJ a