60K Service

Complete 60,000 mile scheduled maintenance service including fluid changes, filter replacements, ignition system service, and comprehensive inspection of all major systems.

Warnings

Tools required

Parts

• Engine oil filter × 1 — FL-1A or equivalent
• Air filter element × 1 — Use OEM specification
• Fuel filter (inline) × 1 — Use OEM specification
• PCV valve × 1 — CV-781C or equivalent
• Spark plugs (Autolite or Motorcraft) × 8 — Autolite 25 or equivalent
• Distributor points set × 1 — Use OEM specification
• Distributor rotor × 1 — Use OEM specification
• Distributor cap × 1 — Use OEM specification
• Condenser × 1 — Use OEM specification
• Differential drain plug gasket × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Place wheel chocks behind rear wheels.
3. Allow engine to cool completely if recently operated.
4. Gather all tools, parts, and fluids before beginning.
5. Raise front of vehicle with floor jack and support on jack stands at frame rails.
6. Remove engine oil filler cap to allow for easier draining.

Procedure

1. 1

   Drain engine oil and replace filter
   Position drain pan under oil pan drain plug. Remove drain plug from oil pan using 5/8" socket and allow oil to drain completely. While draining, use oil filter wrench to remove oil filter (located on right side of engine block). Wipe filter mounting surface clean. Apply thin film of clean oil to new filter gasket, hand-tighten new filter until gasket contacts mounting surface, then tighten an additional 3/4 turn. Reinstall drain plug once oil has fully drained.
2. 2

   Drain and refill rear differential
   Position drain pan under rear differential. Remove the differential drain plug (located at bottom of rear axle housing) using 3/4" socket. Allow fluid to drain completely. Clean drain plug and inspect condition of drain plug gasket; replace if damaged. Reinstall drain plug with new gasket. Locate fill plug on passenger side of differential housing (3/4" square drive). Remove fill plug and use fluid pump to add 80W-90 GL-5 gear oil until fluid reaches bottom of fill hole (approximately 3.5 quarts depending on axle model — fill to bottom of fill hole is the governing measure; verify capacity against the specific rear axle). Reinstall fill plug.
3. 3

   Replace air filter
   Open hood and locate air cleaner assembly atop carburetor. Remove wing nut or clips securing air cleaner lid. Lift lid and remove old air filter element. Inspect air cleaner housing for debris and wipe clean if necessary. Install new air filter element, ensuring proper seating. Reinstall air cleaner lid and secure with wing nut or clips.
4. 4

   Replace fuel filter
   Locate inline fuel filter in fuel line between fuel pump and carburetor (typically mounted on right inner fender or frame rail). Place rags beneath filter to catch fuel spillage. Use two wrenches to hold filter body while loosening inlet and outlet line fittings. Note direction of fuel flow arrow on old filter. Remove old filter and install new filter with arrow pointing toward carburetor. Hand-tighten fittings, then snug with wrenches. Do not overtighten to avoid damaging flare fittings. Wipe up any spilled fuel.
   ⚠Fuel will drain from lines when disconnected. Have rags ready and avoid ignition sources.
5. 5

   Replace PCV valve
   Locate PCV valve in valve cover (typically on driver side valve cover with hose connecting to carburetor base or intake manifold). Pull PCV valve from grommet in valve cover. Disconnect hose from PCV valve. Inspect hose for cracks or deterioration; replace if damaged. Install new PCV valve into hose, then press PCV valve into grommet in valve cover until seated.
6. 6

   Remove and inspect spark plugs
   Label and remove all 8 spark plug wires by pulling on boot, not wire. Use compressed air to blow debris away from spark plug wells. Using 5/8" spark plug socket with extension, remove all 8 spark plugs. Inspect old plugs for wear, fouling, or abnormal electrode condition (note any issues for diagnostic purposes). Set spark plug gap on new plugs to factory specification (approximately 0.034 inches for the 1972 302 with points ignition; verify against tune-up decal) using gap tool. Anti-seize is not required for spark plugs threading into the cast iron cylinder head; if used, apply very sparingly to threads only, avoiding the electrode. Hand-thread each new spark plug into cylinder head to avoid cross-threading, then tighten firmly with spark plug socket. Do not over-tighten. Verified detail (The 1972 Ford 302 V8 with conventional breaker-point ignition typically requires a wider spark plug gap of 0.044 inches, not 0.034 inches. The 0.034" specification is too narrow for this application.): Set spark plug gap on new plugs to 0.044 inches using gap tool.
7. 7

   Service distributor and replace ignition components
   Mark position of distributor rotor and distributor body to engine for reference. Remove distributor cap by releasing 2 spring clips. Inspect cap interior for carbon tracking, cracks, or corrosion; replace if worn (replacing per maintenance schedule). Remove rotor by pulling straight up. Remove the 2 screws holding points set and remove old points and condenser. Install new condenser and new points set, securing with screws but leaving slightly loose for adjustment. Connect primary wire to points terminal. Using feeler gauge, set point gap to factory specification (approximately 0.017 inches for new points; verify against tune-up decal/service manual) by rotating engine with wrench on crankshaft pulley bolt until points are at widest opening, then adjust eccentric screw. Tighten points mounting screws. Install new rotor ensuring it seats fully on distributor shaft. Install new distributor cap and connect all 8 spark plug wires in correct firing order (1-5-4-2-6-3-7-8; distributor rotor rotates counterclockwise on the 302 — verify cap terminal positions against factory documentation before wiring).
8. 8

   Lubricate chassis fittings
   Locate all grease fittings (zerk fittings) on front suspension (upper and lower ball joints, tie rod ends, steering linkage). Clean each fitting with rag. Using grease gun with chassis grease, pump grease into each fitting until clean grease begins to purge from joint boot or resistance is felt. Typical locations include 2 fittings on upper ball joints (one per side), 2 fittings on lower ball joints (one per side), 2-4 fittings on tie rod ends and drag link, 2-3 fittings on steering linkage (pitman arm, idler arm), and 2 fittings on driveshaft universal joints if equipped with greasable u-joints. Verified detail (The 1972 F-100 2WD front suspension uses coil springs with radius arms and typically has ONE grease fitting per ball joint (2 upper, 2 lower = 4 total, not 8) and grease fittings on tie rod ends and drag link. Stating 4 fittings on upper ball joints and 4 on lower is likely double-counted; a 2WD F-100 has only 2 upper and 2 lower ball joints total.): Typical locations include 2 fittings on upper ball joints, 2 fittings on lower ball joints, fittings on each tie rod end and drag link/steering linkage, and fittings on the driveshaft universal joints if equipped with greasable u-joints; verify exact count and locations against factory chassis lubrication chart.
9. 9

   Inspect and top off all fluids
   Check engine coolant level in radiator (cold); add 50/50 coolant mix if low. If equipped with an automatic transmission, check fluid with engine running and transmission in Park; fluid should read between ADD and FULL marks on dipstick (add Type F ATF if needed). If equipped with a manual transmission, check gear oil level at the fill plug instead. Check power steering reservoir and add Type F ATF to FULL mark if needed. Check brake master cylinder reservoir and add DOT 3 brake fluid to fill line if needed. Check windshield washer reservoir and fill with washer fluid. Inspect for any fluid leaks under vehicle.
10. 10

    Refill engine oil
    Lower vehicle from jack stands. Using funnel, add 5 quarts of 10W-30 or 10W-40 conventional motor oil through oil filler opening. Install oil filler cap. Start engine and allow to run for 1 minute, checking for leaks at filter and drain plug. Shut off engine and wait 2 minutes. Check oil level on dipstick; add oil if necessary to bring level to FULL mark.
11. 11

    Set ignition timing
    Connect timing light to number 1 spark plug wire per tool instructions. Locate timing marks on crankshaft pulley and timing tab on front cover. Start engine and allow to warm to operating temperature. With engine idling (disconnect and plug vacuum advance hose if equipped), aim timing light at timing marks. Initial timing should be set per the underhood emissions/tune-up decal (typically around 6 degrees BTDC for the 1972 302 — verify exact figure on the vehicle's decal). If adjustment needed, loosen distributor hold-down bolt, rotate distributor body clockwise to retard or counterclockwise to advance timing until correct mark aligns. Tighten distributor hold-down bolt and recheck timing. Reconnect vacuum advance hose if disconnected.
    ⚠Keep timing light wires and hands clear of moving belts, fan, and pulleys.
12. 12

    Adjust carburetor idle speed
    With engine at normal operating temperature and timing set, adjust idle speed using idle speed screw on carburetor. Turn screw clockwise to increase idle speed or counterclockwise to decrease. Set idle speed to manufacturer specification shown on underhood emission decal (typically 550-600 RPM for automatic in Drive, 700-750 RPM for manual in neutral). Fine-tune idle mixture screws if necessary for smooth idle, turning each screw equally in small increments.
13. 13

    Inspect belts, hoses, and battery
    With engine off, visually inspect all drive belts (fan/alternator, power steering, A/C if equipped) for cracks, glazing, or fraying. Check belt tension by pressing midway between pulleys; deflection should be approximately 1/2 inch. Inspect all coolant hoses and heater hoses for cracks, soft spots, or bulging. Check battery terminals for corrosion; clean with wire brush and battery terminal cleaner if needed. Verify battery hold-down is secure.
14. 14

    Check tire pressure and rotate tires
    Using tire pressure gauge, check pressure in all 4 tires plus spare. Inflate to recommended pressure (typically 32 PSI front, 35 PSI rear; verify on door jamb sticker). Rotate tires in appropriate pattern: for rear-wheel drive, move rear tires to front (same side) and front tires to opposite rear positions. Torque lug nuts in star pattern after rotation.
15. 15

    Final inspection and test drive
    Inspect under vehicle for any fluid leaks. Check that all filler caps are installed and secure. Verify all tools have been removed from engine compartment. Lower hood. Test drive vehicle for 10-15 minutes, checking for proper operation of engine, transmission, brakes, and steering. Listen for unusual noises. After test drive, recheck engine oil level and inspect for leaks. Record service date and mileage.

Reassembly

1. Ensure all drain plugs, fill plugs, and filter assemblies are properly tightened.
2. Verify all fluid levels are correct after engine has run and settled.
3. Double-check that all spark plug wires are routed correctly and seated fully.
4. Confirm distributor cap is secured with both spring clips.
5. Clean any spilled fluids from engine and chassis components.

Verification

• Start engine and verify smooth idle with no abnormal noises or vibrations.
• Check for any fluid leaks from drain plugs, filter, or serviced components.
• Verify oil pressure warning light extinguishes immediately after startup.
• Confirm ignition timing is set to specification using timing light.
• Test drive vehicle and verify normal operation of all systems.
• Recheck engine oil level after test drive with engine off and vehicle level.
• Verify all warning lights function normally on instrument panel.

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