100K Service

Comprehensive 100,000-mile maintenance service including fluid changes, filter replacements, ignition system service, and chassis lubrication for the 1972 Ford F-100 with 302 V8.

Warnings

Tools required

Parts

• Engine oil filter × 1 — FL-1A or equivalent
• Air filter element × 1 — Use OEM specification for 302 V8
• Fuel filter (inline) × 1 — Use OEM specification
• Spark plugs × 8 — Autolite 25 or equivalent (0.034" gap)
• Distributor points set × 1 — Use OEM specification
• Distributor condenser × 1 — Use OEM specification
• Distributor rotor × 1 — Use OEM specification
• Distributor cap × 1 — Use OEM specification
• PCV valve × 1 — Use OEM specification for 302 V8
• Radiator cap × 1 — 13 PSI rating
• Thermostat × 1 — 180°F or 195°F
• Thermostat housing gasket × 1 — Use OEM specification
• Multi-purpose chassis grease (NLGI Grade 2) × 1 — Use OEM specification

Fluids

• 10W-30 or 10W-40 conventional engine oil — 5 qt
• Type F ATF (automatic transmission) — 11 qt
• Ethylene glycol green 50/50 coolant — 15 qt
• 80W-90 GL-5 rear differential oil — 3.5 qt
• DOT 3 brake fluid — 0.75 qt
• Type F ATF (power steering) — 2 qt

Preparation

1. Park vehicle on level ground and apply parking brake firmly.
2. Allow engine to cool completely (minimum 2 hours after last operation).
3. Gather all tools, parts, and fluids before beginning work.
4. Raise front of vehicle with floor jack and support securely on jack stands under frame rails.
5. Raise rear of vehicle and support on jack stands under rear axle housing near differential.
6. Place wheel chocks behind wheels that remain on ground.
7. Open hood and secure in raised position.

Procedure

1. 1

   Drain engine oil and replace filter
   Place drain pan under oil pan drain plug located at rear driver's side of oil pan. Remove drain plug with socket wrench and allow oil to drain completely (approximately 5-10 minutes). While draining, locate oil filter on right side of engine block. Use oil filter wrench to remove old filter by turning counterclockwise. Clean filter mounting surface on block with shop rag. Apply thin film of new oil to rubber gasket on new filter. Install new filter hand-tight, turning until gasket contacts mounting surface, then turn an additional 3/4 turn. Reinstall drain plug once oil has fully drained.
2. 2

   Service automatic transmission
   Locate transmission pan at bottom of transmission case. Place large drain pan underneath. Remove all pan bolts except two at front corners, loosening those two bolts several turns but leaving them engaged. Carefully pry pan loose at rear to allow fluid to drain in controlled manner. Once majority of fluid has drained, remove remaining bolts and lower pan. Remove old gasket material from pan and transmission case using scraper. Clean pan thoroughly and inspect for metal debris (small amount normal, excessive debris indicates internal wear). Replace transmission filter by removing 3 bolts securing filter to valve body. Install new filter with new gasket or O-ring. Install pan with new gasket and tighten bolts in crisscross pattern. Refill transmission through dipstick tube with approximately 3-4 quarts Type F ATF initially (pan drop retains fluid in torque converter). Do not add the full dry-fill capacity; check level with dipstick and add incrementally. Start engine, allow to warm, cycle through all gear positions, then recheck level with engine running in Park. Verified detail (11 quarts is the total system capacity; refill after pan drop is approximately 4-5 quarts. Overfilling by 6+ quarts would cause severe transmission damage.): Refill transmission through dipstick tube with approximately 4-5 quarts Type F ATF (pan service refill amount, not total capacity).
3. 3

   Drain and refill cooling system
   Ensure engine is completely cold. Place drain pan under radiator. Open radiator drain petcock located at bottom driver's side of radiator (turn counterclockwise) or remove lower radiator hose at radiator. Remove radiator cap to allow system to drain fully. Once drained, close petcock or reinstall lower hose with hose clamp. Remove thermostat housing (located at front of engine block where upper radiator hose connects) by removing bolts (typically 2-3 depending on housing style). Remove old thermostat and clean mating surfaces thoroughly. Install new thermostat with spring side facing toward engine block. Install new gasket and reinstall housing. Slowly fill cooling system through radiator neck with 50/50 premixed coolant until full. Install new radiator cap. Start engine and allow to reach operating temperature while monitoring for leaks. Top off coolant as needed once engine reaches operating temperature and thermostat opens.
4. 4

   Service rear differential
   Locate differential fill plug on front face of differential housing (3/8" square drive fitting). Remove fill plug first to ensure it's not seized before draining. Locate drain plug at bottom rear of differential housing. Place drain pan underneath and remove drain plug, allowing oil to drain completely. Once drained, reinstall drain plug and tighten securely. Using fluid pump with appropriate hose adapter, pump 80W-90 GL-5 gear oil into fill hole until oil begins to flow back out of fill hole (approximately 3.5 pints; fill until level with bottom of fill hole threads). Oil should be level with bottom of fill hole threads. Reinstall fill plug and tighten securely.
5. 5

   Replace air filter
   Locate round air cleaner housing on top of carburetor. Remove wing nut or clips securing air cleaner lid. Lift off lid and remove old air filter element. Inspect inside of air cleaner housing for dirt and debris; wipe clean if necessary. Install new air filter element with pleats running vertically. Reinstall air cleaner lid and secure with wing nut or clips.
6. 6

   Replace inline fuel filter
   Locate inline fuel filter in fuel line at the carburetor inlet (on many 302 applications the filter threads into or sits just before the carburetor fuel inlet; some have an inline filter along the fuel line). Verify actual location before proceeding. Place shop rag under filter to catch residual fuel. Using pliers, squeeze and slide spring clamps away from filter on both fuel line connections. Pull fuel lines off filter nipples (expect small amount of fuel spillage). Note arrow on filter body indicating direction of fuel flow. Install new filter with arrow pointing toward carburetor. Slide fuel lines onto filter nipples and reposition spring clamps over connections on hose side of filter barbs.
7. 7

   Replace spark plugs
   Number the spark plug wires 1-8 using masking tape before removal (1-4 right/passenger bank front to rear, 5-8 left/driver bank front to rear; firing order 1-5-4-2-6-3-7-8). Remove spark plug wires by grasping boot at plug and twisting while pulling. Using spark plug socket, remove all 8 spark plugs. Inspect old plugs for wear patterns and fouling. Gap new spark plugs to 0.034" using gap tool. Install plugs hand-tight, then torque to 15-20 ft-lbs (cast-iron head, gasketed plug). If anti-seize is used on threads, reduce torque slightly to avoid over-tightening; avoid getting any compound on the electrodes. Reconnect spark plug wires to correct cylinders following firing order. Verified detail (15 ft-lbs is very low for spark plugs in cast iron heads. The 1972 302 has cast iron heads; typical torque is 25-30 ft-lbs for tapered seat plugs or 10-15 ft-lbs with gasket seat plugs. Need to verify plug type.): install plugs hand-tight, then torque to 25-30 ft-lbs (for tapered seat plugs in cast iron heads) or 10-15 ft-lbs (for gasket seat plugs)
8. 8

   Replace distributor points, condenser, cap, and rotor
   Remove distributor cap by releasing 2 spring clips or removing 2 screws. Mark position of rotor pointing direction relative to distributor body with chalk or marker. Remove rotor by pulling straight up. Disconnect primary wire and condenser wire from points set. Remove 2 screws securing points to breaker plate and remove old points and condenser. Install new condenser and secure mounting screw. Install new points set and secure with 2 screws (leave slightly loose for adjustment). Reconnect primary wire and condenser wire to points terminal. Rotate engine by hand using wrench on crankshaft pulley bolt until points are at widest gap (rubbing block on points is on high point of distributor cam lobe). Adjust point gap to 0.021" using feeler gauge by loosening points screws slightly, adjusting eccentric screw or sliding points base, then retightening screws. Install new rotor aligning with shaft slot. Inspect inside of new distributor cap for cracks or carbon tracking. Transfer spark plug wires one at a time from old cap to new cap in same positions. Install new distributor cap and secure with clips or screws.
9. 9

   Replace PCV valve
   Locate PCV valve in rubber grommet on driver's side valve cover. Grasp PCV valve and pull upward firmly to remove from grommet (may require twisting motion). Disconnect hose from PCV valve. Install new PCV valve into hose, then press valve firmly into grommet in valve cover until seated. Ensure hose is connected to intake manifold vacuum source.
10. 10

    Service brake system
    Locate brake master cylinder on driver's side firewall. Clean around master cylinder cap before removing to prevent contamination. Remove cap and check fluid level. If fluid is dark or contaminated, use turkey baster or fluid pump to remove old fluid from reservoir. Refill with fresh DOT 3 brake fluid to proper level (1/4" below top of reservoir). Inspect fluid level in reservoir and condition. If vehicle has experienced brake fade or fluid appears very dark, consider complete brake fluid flush. Reinstall cap securely.
11. 11

    Service power steering system
    Locate power steering reservoir (typically mounted on pump on front driver's side of engine). Clean around cap before removing. Check fluid level with engine off; level should be at FULL COLD mark on dipstick or visible through reservoir. If low, add Type F ATF until proper level is reached. Inspect hoses and connections for leaks or deterioration. Start engine and turn steering wheel lock to lock several times to purge air. Recheck level with engine running; add fluid if needed to bring to proper level. Fluid should be red and clear, not dark or burnt smelling.
12. 12

    Lubricate chassis and suspension
    Using grease gun with flexible hose, lubricate all grease fittings on chassis and suspension. Typical locations include: steering linkage (tie rod ends, drag link, pitman arm), front suspension (upper and lower ball joints on each side), driveshaft universal joints (front and rear), and spring shackles. Apply grease until fresh grease appears at seals or joints (typically 2-3 pumps per fitting). Wipe away excess grease. Count and verify all fittings have been serviced (typical truck has 8-12 grease fittings depending on configuration).
13. 13

    Inspect belts and hoses
    Visually inspect all drive belts (alternator, power steering, water pump) for cracks, glazing, fraying, or excessive wear. Check belt tension by pressing on longest span; belt should deflect approximately 1/2" under moderate thumb pressure. If belts are cracked or glazed, mark for replacement. Inspect all cooling system hoses for cracks, soft spots, or deterioration. Squeeze hoses to check for internal deterioration (should feel firm, not squishy). Check hose clamps for tightness. Inspect heater hoses and bypass hoses. Replace any hoses showing signs of deterioration.
14. 14

    Set ignition timing and adjust idle
    Connect timing light to number 1 spark plug wire following tool manufacturer's instructions. Start engine and allow to reach normal operating temperature. Locate timing marks on harmonic balancer and timing tab on front cover. With engine idling, aim timing light at timing marks. Loosen distributor hold-down bolt just enough to allow distributor rotation. Rotate distributor body slowly until timing mark aligns with specification (typically 6 degrees BTDC for 1972 302 V8 with vacuum advance disconnected and hose plugged). Tighten distributor hold-down bolt. Reconnect vacuum advance line if disconnected. Verify timing with timing light. Adjust idle speed screw on carburetor to achieve approximately 650 RPM in Drive (with automatic transmission). Adjust idle mixture screws for smoothest idle (turn in until engine begins to stumble, then back out 1/4 to 1/2 turn). Verified detail (1972 was an emissions-transition year; initial timing for the 302 can vary (often around 6 BTDC, sometimes TDC depending on transmission and emissions calibration). The range should be verified against the underhood emissions decal for this specific vehicle.): per the underhood emissions/tune-up decal for this specific vehicle (typically around 6 degrees BTDC for 1972 302 V8 with vacuum advance disconnected — verify against decal)

Reassembly

1. Lower vehicle from jack stands carefully after verifying all drain plugs and fill plugs are reinstalled and tightened.
2. Refill engine with 5 quarts of 10W-30 or 10W-40 conventional motor oil through oil filler cap on driver's side valve cover.
3. Start engine and verify oil pressure light extinguishes within 3-5 seconds.
4. Visually inspect under vehicle for any fluid leaks from oil pan, transmission pan, differential, or cooling system.
5. Allow engine to idle for 5 minutes while monitoring temperature gauge and checking for leaks.
6. Shut off engine and recheck all fluid levels after 5-minute settling period: engine oil, transmission fluid, coolant, brake fluid, and power steering fluid.
7. Top off fluids as necessary to proper levels.
8. Test drive vehicle and verify proper operation of all systems serviced.

Verification

• Check engine oil level on dipstick with engine off and vehicle level; oil should be between ADD and FULL marks.
• Check transmission fluid level with engine running at operating temperature in Park; fluid should be in HOT range on dipstick.
• Verify coolant is visible in radiator neck with engine cold and coolant recovery tank is at proper level.
• Check for any fluid leaks under vehicle after test drive; no drips should be present.
• Verify engine starts easily and idles smoothly between 600-700 RPM with no missing or rough running.
• Confirm engine reaches normal operating temperature (160-190°F) and does not overheat.
• Test drive vehicle and verify smooth acceleration, proper transmission shifting, and no unusual noises from drivetrain.
• Verify steering operates smoothly without unusual noises and brakes function properly with firm pedal.
• Confirm all service reminder stickers or maintenance records are updated with date and mileage.

More procedures for this vehicle