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Why the Ford Pinto didn’t suck

Why the Ford Pinto didn't suckThe Ford Pinto was born a low-rent, stumpy thing in Dearborn 40 years ago and grew to become one of the most infamous cars in history. The thing is that it didn't actually suck. Really.

Even after four decades, what's the first thing that comes to mind when most people think of the Ford Pinto? Ka-BLAM! The truth is the Pinto was more than that — and this is the story of how the exploding Pinto became a pre-apocalyptic narrative, how the myth was exposed, and why you should race one.

The Pinto was CEO Lee Iacocca's baby, a homegrown answer to the threat of compact-sized economy cars from Japan and Germany, the sales of which had grown significantly throughout the 1960s. Iacocca demanded the Pinto cost under $2,000, and weigh under 2,000 pounds. It was an all-hands-on-deck project, and Ford got it done in 25 months from concept to production.

Building its own small car meant Ford's buyers wouldn't have to hew to the Japanese government's size-tamping regulations; Ford would have the freedom to choose its own exterior dimensions and engine sizes based on market needs (as did Chevy with the Vega and AMC with the Gremlin). And people cold dug it.

When it was unveiled in late 1970 (ominously on September 11), US buyers noted the Pinto's pleasant shape — bringing to mind a certain tailless amphibian — and interior layout hinting at a hipster's sunken living room. Some call it one of the ugliest cars ever made, but like fans of Mischa Barton, Pinto lovers care not what others think. With its strong Kent OHV four (a distant cousin of the Lotus TwinCam), the Pinto could at least keep up with its peers, despite its drum brakes and as long as one looked past its Russian-roulette build quality.

But what of the elephant in the Pinto's room? Yes, the whole blowing-up-on-rear-end-impact thing. It all started a little more than a year after the Pinto's arrival.

 

Grimshaw v. Ford Motor Company

On May 28, 1972, Mrs. Lilly Gray and 13-year-old passenger Richard Grimshaw, set out from Anaheim, California toward Barstow in Gray's six-month-old Ford Pinto. Gray had been having trouble with the car since new, returning it to the dealer several times for stalling. After stopping in San Bernardino for gasoline, Gray got back on I-15 and accelerated to around 65 mph. Approaching traffic congestion, she moved from the left lane to the middle lane, where the car suddenly stalled and came to a stop. A 1962 Ford Galaxie, the driver unable to stop or swerve in time, rear-ended the Pinto. The Pinto's gas tank was driven forward, and punctured on the bolts of the differential housing.

As the rear wheel well sections separated from the floor pan, a full tank of fuel sprayed straight into the passenger compartment, which was engulfed in flames. Gray later died from congestive heart failure, a direct result of being nearly incinerated, while Grimshaw was burned severely and left permanently disfigured. Grimshaw and the Gray family sued Ford Motor Company (among others), and after a six-month jury trial, verdicts were returned against Ford Motor Company. Ford did not contest amount of compensatory damages awarded to Grimshaw and the Gray family, and a jury awarded the plaintiffs $125 million, which the judge in the case subsequently reduced to the low seven figures. Other crashes and other lawsuits followed.

Why the Ford Pinto didn't suck

Mother Jones and Pinto Madness

In 1977, Mark Dowie, business manager of Mother Jones magazine published an article on the Pinto's "exploding gas tanks." It's the same article in which we first heard the chilling phrase, "How much does Ford think your life is worth?" Dowie had spent days sorting through filing cabinets at the Department of Transportation, examining paperwork Ford had produced as part of a lobbying effort to defeat a federal rear-end collision standard. That's where Dowie uncovered an innocuous-looking memo entitled "Fatalities Associated with Crash-Induced Fuel Leakage and Fires."

The Car Talk blog describes why the memo proved so damning.

In it, Ford's director of auto safety estimated that equipping the Pinto with [an] $11 part would prevent 180 burn deaths, 180 serious burn injuries and 2,100 burned cars, for a total cost of $137 million. Paying out $200,000 per death, $67,000 per injury and $700 per vehicle would cost only $49.15 million.

The government would, in 1978, demand Ford recall the million or so Pintos on the road to deal with the potential for gas-tank punctures. That "smoking gun" memo would become a symbol for corporate callousness and indifference to human life, haunting Ford (and other automakers) for decades. But despite the memo's cold calculations, was Ford characterized fairly as the Kevorkian of automakers?

Perhaps not. In 1991, A Rutgers Law Journal report [PDF] showed the total number of Pinto fires, out of 2 million cars and 10 years of production, stalled at 27. It was no more than any other vehicle, averaged out, and certainly not the thousand or more suggested by Mother Jones.

Why the Ford Pinto didn't suck

The big rebuttal, and vindication?

But what of the so-called "smoking gun" memo Dowie had unearthed? Surely Ford, and Lee Iacocca himself, were part of a ruthless establishment who didn't care if its customers lived or died, right? Well, not really. Remember that the memo was a lobbying document whose audience was intended to be the NHTSA. The memo didn't refer to Pintos, or even Ford products, specifically, but American cars in general. It also considered rollovers not rear-end collisions. And that chilling assignment of value to a human life? Indeed, it was federal regulators who often considered that startling concept in their own deliberations. The value figure used in Ford's memo was the same one regulators had themselves set forth.

In fact, measured by occupant fatalities per million cars in use during 1975 and 1976, the Pinto's safety record compared favorably to other subcompacts like the AMC Gremlin, Chevy Vega, Toyota Corolla and VW Beetle.

And what of Mother Jones' Dowie? As the Car Talk blog points out, Dowie now calls the Pinto, "a fabulous vehicle that got great gas mileage," if not for that one flaw: The legendary "$11 part."

Why the Ford Pinto didn't suck

Pinto Racing Doesn't Suck

Back in 1974, Car and Driver magazine created a Pinto for racing, an exercise to prove brains and common sense were more important than an unlimited budget and superstar power. As Patrick Bedard wrote in the March, 1975 issue of Car and Driver, "It's a great car to drive, this Pinto," referring to the racer the magazine prepared for the Goodrich Radial Challenge, an IMSA-sanctioned road racing series for small sedans.

Why'd they pick a Pinto over, say, a BMW 2002 or AMC Gremlin? Current owner of the prepped Pinto, Fox Motorsports says it was a matter of comparing the car's frontal area, weight, piston displacement, handling, wheel width, and horsepower to other cars of the day that would meet the entry criteria. (Racers like Jerry Walsh had by then already been fielding Pintos in IMSA's "Baby Grand" class.)

Bedard, along with Ron Nash and company procured a 30,000-mile 1972 Pinto two-door to transform. In addition to safety, chassis and differential mods, the team traded a 200-pound IMSA weight penalty for the power gain of Ford's 2.3-liter engine, which Bedard said "tipped the scales" in the Pinto's favor. But according to Bedard, it sounds like the real advantage was in the turns, thanks to some add-ons from Mssrs. Koni and Bilstein.

"The Pinto's advantage was cornering ability," Bedard wrote. "I don't think there was another car in the B. F. Goodrich series that was quicker through the turns on a dry track. The steering is light and quick, and the suspension is direct and predictable in a way that street cars never can be. It never darts over bumps, the axle is perfectly controlled and the suspension doesn't bottom."

Need more proof of the Pinto's lack of suck? Check out the SCCA Washington, DC region's spec-Pinto series.

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My Somewhat Begrudging Apology To Ford Pinto

ford-pinto.jpg

I never thought I’d offer an apology to the Ford Pinto, but I guess I owe it one.

I had a Pinto in the 1970s. Actually, my wife bought it a few months before we got married. The car became sort of a wedding dowry. So did the remaining 80% of the outstanding auto loan.

During a relatively brief ownership, the Pinto’s repair costs exceeded the original price of the car. It wasn’t a question of if it would fail, but when. And where. Sometimes, it simply wouldn’t start in the driveway. Other times, it would conk out at a busy intersection.

It ranks as the worst car I ever had. That was back when some auto makers made quality something like Job 100, certainly not Job 1.

Despite my bad Pinto experience, I suppose an apology is in order because of a recent blog I wrote. It centered on Toyota’s sudden-acceleration problems. But in discussing those, I invoked the memory of exploding Pintos, perpetuating an inaccuracy.

The widespread allegation was that, due to a design flaw, Pinto fuel tanks could readily blow up in rear-end collisions, setting the car and its occupants afire.

People started calling the Pinto “the barbecue that seats four.” And the lawsuits spread like wild fire.

Responding to my blog, a Ford (“I would very much prefer to keep my name out of print”) manager contacted me to set the record straight.

He says exploding Pintos were a myth that an investigation debunked nearly 20 years ago. He cites Gary Schwartz’ 1991 Rutgers Law Review paper that cut through the wild claims and examined what really happened.

Schwartz methodically determined the actual number of Pinto rear-end explosion deaths was not in the thousands, as commonly thought, but 27.

In 1975-76, the Pinto averaged 310 fatalities a year. But the similar-size Toyota Corolla averaged 313, the VW Beetle 374 and the Datsun 1200/210 came in at 405.

Yes, there were cases such as a Pinto exploding while parked on the shoulder of the road and hit from behind by a speeding pickup truck. But fiery rear-end collisions comprised only 0.6% of all fatalities back then, and the Pinto had a lower death rate in that category than the average compact or subcompact, Schwartz said after crunching the numbers. Nor was there anything about the Pinto’s rear-end design that made it particularly unsafe.

Not content to portray the Pinto as an incendiary device, ABC’s 20/20 decided to really heat things up in a 1978 broadcast containing “startling new developments.” ABC breathlessly reported that, not just Pintos, but fullsize Fords could blow up if hit from behind.

20/20 thereupon aired a video, shot by UCLA researchers, showing a Ford sedan getting rear-ended and bursting into flames. A couple of problems with that video:

One, it was shot 10 years earlier.

Two, the UCLA researchers had openly said in a published report that they intentionally rigged the vehicle with an explosive.

That’s because the test was to determine how a crash fire affected the car’s interior, not to show how easily Fords became fire balls. They said they had to use an accelerant because crash blazes on their own are so rare. They had tried to induce a vehicle fire in a crash without using an igniter, but failed.

ABC failed to mention any of that when correspondent Sylvia Chase reported on “Ford’s secret rear-end crash tests.”

We could forgive ABC for that botched reporting job. After all, it was 32 years ago. But a few weeks ago, ABC, in another one of its rigged auto exposes, showed video of a Toyota apparently accelerating on its own.

Turns out, the “runaway” vehicle had help from an associate professor. He built a gizmo with an on-off switch to provide acceleration on demand. Well, at least ABC didn’t show the Toyota slamming into a wall and bursting into flames.

In my blog, I also mentioned that Ford’s woes got worse in the 1970s with the supposed uncovering of an internal memo by a Ford attorney who allegedly calculated it would cost less to pay off wrongful-death suits than to redesign the Pinto.

It became known as the “Ford Pinto memo,” a smoking gun. But Schwartz looked into that, too. He reported the memo did not pertain to Pintos or any Ford products. Instead, it had to do with American vehicles in general.

It dealt with rollovers, not rear-end crashes. It did not address tort liability at all, let alone advocate it as a cheaper alternative to a redesign. It put a value to human life because federal regulators themselves did so.

The memo was meant for regulators’ eyes only. But it was off to the races after Mother Jones magazine got a hold of a copy and reported what wasn’t the case.

The exploding-Pinto myth lives on, largely because more Americans watch 20/20 than read the Rutgers Law Review. One wonders what people will recollect in 2040 about Toyota’s sudden accelerations, which more and more look like driver error and, in some cases, driver shams.

So I guess I owe the Pinto an apology. But it’s half-hearted, because my Pinto gave me much grief, even though, as the Ford manager notes, “it was a cheap car, built long ago and lots of things have changed, almost all for the better.”

Here goes: If I said anything that offended you, Pinto, I’m sorry. And thanks for not blowing up on me.

A Native Texan with a Native Texan 78 Pony, a. k. a. "Old Faithful"

Started by 78txpony, April 01, 2009, 08:49:40 AM

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popbumper

Rob stopped over last night, and '76 wagon got to meet '78 sedan. Rob took some pics, I will post later today when I resize them. We had a nice meeting, and he took my son and I for a ride. What fun!

Chris
Restoring a 1976 MPG wagon - purchased 6/08

blupinto

Hold on, Rob. I looked in my Haynes Pinto book ('75-'80) and sure enough it says the manual tranny is "of German manufacture". So it's not a rumor.  ;D
One can never have too many Pintos!

blupinto

Ohhhh, I've never had a Pinto older than a '74, and none that were stick-shift, so I don't know about the manuals being made in Germany. Chuck might know. I am flattered you asked, though... ;)
One can never have too many Pintos!

78txpony

Many thanks for the additional welcomes!  :)
My next big project will be the second valve stem seal replacement and radiator repair and coolant flush.  My car has the ORIGINAL HEATER HOSES on it because I did not want to pull the heater box out from under the dash...  Is that how you change the hoses??  I have a bypass hose with clamps in the trunk in case of a rupture. 

blupinto - I had heard the manual 78 tranny was German made - any fact or fiction on this?  ???
-Rob
-Rob Young
1978 Pinto Pony sedan (Old Faithful) a.k.a. "the Tramp"
http://www.flickr.com/photos/thelonerider2005/sets
1972 Cutlass Supreme Convertible (442 clone) -"Lady" (My mistress...)
http://www.flickr.com/photos/robsalbum/sets
1986 Cutlass Supreme Coupe - "Pristine"
1997 H-D Sportster

dga57

 :welcome:  Rob!

I enjoyed reading about you and your Pinto!  Will look forward to more posts from you.

Dwayne :smile:
Pinto Car Club of America - Serving the Ford Pinto enthusiast since 1999.

discolives78

Well, thanks for the introduction, Dave! ;)

Hello Rob!  :welcome: to the corral!

I've heard a bit about you already from Popbumper. I read your tale and we also have much in common, but I have had it just a bit better I guess. I have a 1978 Pinto sedan that was also wrecked in front and put back together. I too have had my cluster out (more than once) but I got lucky I guess. My cluster is still in one piece! My car came from a good friend who was the original owner's daughter. She also happened to be my sister-in-law's mom's roommate. So the car has been around me for quite a while. It was spared the dreaded 'learning to drive' duty, it's always been adult owned, so that helps.

Chuck :afro:


A virtual version of my last Pinto. Was Registered Ride #111. Missed every day.

blupinto

I was talking to a friend at work the other day. He was admiring my Pinto and it occured to me that this Pinto was truly American-made. What modern-day American car can really claim that anymore? I've had to replace a fuel and a water pump, the timing belt, some hoses... but other than that she's all American baby! Well, then there's the tires...

      What I love about these old gems is they're not only scarce, but an average person can work on them. And yes, I confess to giving my Wildfire love and affection!  :-* :hypno: :surprised: :) ;) :D ;D :lol:
One can never have too many Pintos!

78txpony

I would much rather have a car that you cannot obtain with a little credit and signing some papers at a dealer.  I like old stuff and I am a unique person, so I want something different that demands attention.  Old cars (and other stuff) will always be a way of life for me.  :)  I want to be able to work on them, too, if needed...

The main reason i want to keep this car (other than it being in our family since new) is to prove a point on how long the old stuff can last, given some BASIC maintanence.  No love and affection, just common-sense PM now and then.  A new car would become too much of a pain to try to run for 30+ years...

blupinto,
I just copy and pasted from a journal I have been keeping.  I just started one for the Pinto and my Olds one is about 30 pages+ already!   :hypno:
Thanks for the timeout forewarning!
-Rob Young
1978 Pinto Pony sedan (Old Faithful) a.k.a. "the Tramp"
http://www.flickr.com/photos/thelonerider2005/sets
1972 Cutlass Supreme Convertible (442 clone) -"Lady" (My mistress...)
http://www.flickr.com/photos/robsalbum/sets
1986 Cutlass Supreme Coupe - "Pristine"
1997 H-D Sportster

popbumper

..."posh neighborhoods"... ::)

You know, seeing exotic cars (Ferraris, Astons, Lamborghinis) around these places is >always< cool, BUT, I'd easily put my money on Pintos being more rare than those cars....

...which is one of the many reasons it's great to have one. :P

Chris
Restoring a 1976 MPG wagon - purchased 6/08

blupinto

Rob, how did you write that without running out of time? Maybe it's just my idiot computer but every time I try to write something long it gets erased and the screen says I "ran out of time".

Great story about your little warrior. I like driving my '74 in posh neighborhoods too... ;D
One can never have too many Pintos!

78txpony

Thank you for the welcome, guys!   :)
This little car has made a lot of history in our family.  My mom keeps trying to convince me to get rid of it, but considering the paltry 600 bucks I would get, I would just keep driving it.  As time goes on, I am slowly getting it back in better shape, though not restored.  Each thing I did lately has made such a big improvement to the car, it makes even LESS sense to get rid of it.  I am amazed how well it drives now!

I know it is WAY out of place here in Dallas with all the faddy and high $$ cars, but all I can think is that it is reliable, paid for since day 1, and will have outlived all these complex new cars.  I always find it ammusing to drive through the posh neighborhoods with it...  ;D

As some have realized, I enjoy writing too. 

If interested, feel free to check out my main Oldsmobile resto project here: http://www.flickr.com/photos/robsalbum/sets/72157602930020786/

Dave, I need to hear your story some time... 
-Rob Young
1978 Pinto Pony sedan (Old Faithful) a.k.a. "the Tramp"
http://www.flickr.com/photos/thelonerider2005/sets
1972 Cutlass Supreme Convertible (442 clone) -"Lady" (My mistress...)
http://www.flickr.com/photos/robsalbum/sets
1986 Cutlass Supreme Coupe - "Pristine"
1997 H-D Sportster

dave1987

I feel like I"m reading the story of my own car! lol! Down to the mother buying it new in 78 and the car teaching several siblings to drive a stick, and further down to body panels not lining up!

Very nice story, I love reading these.

Nice to meet a fellow 78 Sedan owner! You should see chuck replying to this thread soon too.....:P
1978 Ford Pinto Sedan - Family owned since new

Remembering Jeff Fitcher with every drive in my 78 Sedan.

I am a Pinto Surgeon. Fixing problems and giving Pintos a chance to live again is more than a hobby, it's a passion!

beegle55

 :welcome: and thanks for posting. My Pinto too has 156K... minus the original clutch, which was replaced in '06. It did have the original tailpipe up until a leak caused me to replace it. Really realiable cars actually.

    -beegle55
2005 Jeep GC 5.7 HEMI
1993 Ford Mustang
1991 Ford Mustang GT
1988 Ford Mustang
1980 Ford Pinto Cruising- Mint, Fully documented
1979 Ford Pinto Trunk- 2.3L 4 speed
1978 Ford Pinto HB- 302 drag car
1976 Ford Pinto Runabout- 40,000 mi, V6
1972 Ford Maverick Grabber (real)
1970 Ford Mustang 302

popbumper

Wow, Rob, GREAT writeup!! I urged Rob yesterday to submit a post explaining who he was and what he had, on the heels of some messaging in the "Pinto names" thread where Texas members were mentioned.

The rest of the story - as you all know, I have a '76 wagon, in Medium chestnut brown metallic, and tan interior. Aside from the dash (black), Rob's car is identical for color and materials (and two years newer). We both own Texas cars, he lives a few miles from me, he works at a large company that I used to....strange world!!

Rob is my newest best friend  ;D.

Thanks for sharing Rob, like I said, when we get them in the driveway together, I'll snap a shot and post here. What a hoot!!

Chris
Restoring a 1976 MPG wagon - purchased 6/08

78txpony

Greetings Pinto owners!  My name is Rob Young from Dallas.  Although I am somewhat new to this site, I am nowhere new to Pintos.
I promised an intro a while back so here it is...  I also include the recent work done on the car, bringing it back to better life!

My mom had bought a 1978 Pony Sedan brand new from Town East Ford back in 1978. She specially ordered it STRIPPED!  It had no options whatsoever - the cheapest, lightest, most trouble-free one you could get then... Medium Chestnut metallic paint, black dash, tan interior, 2.3L with 4-on-the-floor.   She traded a 1970 Galaxie 500 with a 429 and I still don't forgive her!!   hehe...  Pictures can be seen at  http://www.flickr.com/photos/thelonerider2005/sets/72157603769350277/

That old Pinto served my mom until 1986 when she bought a new Olds Cutlass.  The Pinto went to my sister for her high-school car and she used it until she got a new hundai back in 1989.  I got the Pinto then for my high school car and had it ever since.  Surprisingly, it taught 5 people how to drive a standard shift and it still has the original clutch, 152K miles later. 

Although I bought a few newer cars since 1989, I wanted to keep the old Pinto since it was very reliable and easy and cheap to maintain myself.  It was a good backup and loaner car, too (although I do not loan it (or any of my cars) out any more)... 
It has been in 6 wrecks and was totalled 4 times due to crappy dallas drivers...  It was fixed just enough each time to keep it drivable and it still runs good for what it is.  None of the body panels in front line up perfectly anymore, nor does the left rear interior trim.  The roof has a slight buckle at the top of the windshield.
For those reasons (structural damage), i will not actually restore it, but keep it as a surviving daily driver. It still has the original exhaust system, starter, alternator (with new brushes), regulator, ignition module, clutch, transmission, transmission oil (you heard right!), axle, rear suspension, interior, and more. 

Front left seat and carpet are trashed, but other seats are okay, tho faded. Headliner needs restitching in the center and the right sunvisor needs welding.  Dash is still an amazing 9 out of 10 - no cracks! That silicon spray stuff and folding sunshades DO help!  We used them mainly because it makes the car cooler and there is no A/C...

In all it has been very cheap and easy to run and maintain.  If you can work on lawnmowers, then you can work on this - Pintos are simple.  I think my mom spent 3000 for this car back in 78 and since we have every repair, oil change, and PM on record, we all spent a total of about 3500 on all tires, batteries, repairs and maintanence (only excluding oil changes) throughout its 31 year life so far - not bad! 
It has left me stranded only once, back on Feb 29, 2000 when i neglected to replace the timing belt at the correct interval.  After ~65K miles, it jumped a tooth and the engine died.  My fault, entirely, and it was a cheap belt, too...  The ignition switch lock froze up at an ex GF's house 10 years ago, but I was able to change it there without issue. 
Back in 2003, I decided i would keep the car a while longer and I rebuilt the ENTIRE front end - by myself!  It needed ball joints, but I decided to go all the way while it was apart.  It was not too bad of a project either... It drove like any new car in its class (or one above!) afterwards.   I had added a front sway bar 20 years ago and that improved handling a lot.

I have just finished replacing all of the rotten door and window weatherstripping...
There is a noticable difference in reduced body flexing and door / window rattling with new seals!  Topsdown.com provided the custom Pinto seals which fit quite well. However, since this car was involved in a bad frontal crash back in '87, there was extensive chassis damage and even the roof had shifted a quarter inch or so.  As a result, the seal on the right door had to be modified and additional weatherstrip has to be added int he window areas to provide a tight seal. 
The trunk seal was replaced a few weeks after.  This has not been reproduced (through my research), so i improvised... 
My main project car is a 1972 Olds 442 clone convertible and I noticed the trunk seal on it is similar!  So I bought one for that car (GM A-body) for only 15 bucks and installed it on the Pinto.  It is the Metro brand, about 17' long.  I used only about 9' of it on the tiny Pinto trunk.  This brand has two hollow section, which makes it very soft and pliable. 
The old 30+ year-old seal had to be scraped out with popsicle sticks with sharp "edges" cut into them like a chisel.  This helped protect the paint.  Razor blades took the thick sections out.  I also had to reshape some sheetmetal back there, as it was still buckled slightly from three rear-end wrecks long ago.  There is no channel to insert the weatherstrip in (just one lip) and no clips.  Therefore the entire seal must be glued on with 3M black weatherstrip cement, all the way around on the bottom and lip of the sheetmetal.  This would need to be done even with a factory NOS seal.  It was tedious, but it went well.  I left the lid open an hour after it all dried and it stayed in place well.  The lid was hard to get closed for a week or two, but now it closes like it did when new and it seems to seal well - I had no leakage through the past several rains! 

The tale of the dreaded headlight switch:
"May my misfortunes be entertainment to others!" Headlight switch headaches - the repair of one minor thing leads to the destruction of a major...

Does any car made have an easily-accessible headlight switch? Out of 3 cars I have ever worked on, the HL switches are all in the most unaccessible part of the dash. The instrument clusters had to come out in all three cases.

Just recently I had to replace the headlight switch in the 78 Pinto, as it had developed the flashing headlight syndrome (bad internal circuit breaker). 
It WAS a dark and windy night and my rechargable flashlight kept going dead.......
The HL switch was at the very lower left of the dash, but it was totally enclosed by steel brackets with inaccessible bolts. I tried loosening some but failed. What was the guy on who designed this mess??
So, the instrument cluster had to come out... Just remove two screws and pop the speedo cable - easy huh? I pulled the screws and pushed the speedo release clip and gave a light tug...

"This is the way the cluster crumbles!!"
A tug on the cable yielded a hideous CRUNCH,  like the first chew of a mouthful of Pringles... The back plastic cover of the instrument cluster came apart like a dollar watch...
I knew the last time I had this out 10 years ago, it was not in the best shape but I never thought it would self destruct in my hands like this.
The simple weight of the speedo cause it to crumble more as I tilted it up to clear the steering wheel.
Well this explains why none of the idiot lights and cluster lights worked anymore - all electrical contacts on the flex-circuit were lost as there was no backup material. It had lots of rattles, as it was all loose inside.  This plastic feels about like a thin hard cookie and crumbles like one also.

BUT WAIT - THERE'S MORE (bad luck)!
I squeezed the new HL switch back in and finally got the bezel screwed on (I could have used 3 hands...) I then found that the knob and shaft would not stay in the switch! #&@#^$#!
I pulled the bezel, yanked the switch out, and found the knob and shaft went in and secured fine. #&@#^$#!#&@#^$#! I pulled the knob and shaft, I fought the little #&@#^$#! back in there and secured it. #&@#^$#! shaft still would not stay in again!!
#&@#^$#!#&@#^$#!#&@#^$#!#!#&@#^$#!#&@#^$#!
I ripped the thing out again and forcefully pulled the knob off of shaft. Pushed shaft in switch - shaft stayed in switch. Crammed switch back in and secured it. Shaft stayed in. Pushed knob on shaft and surprisingly, it all stayed together and it even worked right this morning! What the heck is up with all that?! I guess the Ford Gods are against me. Geez...  "In Olds I Trust..."

CLUSTER F---ED...
A quick internet search showed that this is a 99% problem in all of these clusters - it was a poorly made plastic that easily deteriorates - it looks like polystyrene to me... Noone reproduces these and even rare NOS ones for 100 bucks + will have that problem...  Until I find a solution, a new temporary speedo housing was built out of cardboard.  I call it a prototype...

I got the Ford cluster apart very carefully (it pretty much fell apart) and only the back white cover is crumbly. The rest of it was fine. 
I passed up any possiblity to glue or coat it, as you can see how much it crumbled just by removing the flex circuit and fuel gauge.
I finally got on this forum to see if anyone could help.
Luckily a member here sold me a spare (wow!) cluster and allowed me to get my dash looking better! 
When I received it, I removed the back cover which was very much intact and washed it good.  Now it does show signs of deterioration in its infant stages...
I heard of coating these covers with PVC cement, but I figured I had something even better - POR15! 
So I painted one coat of POR15 clear on my old crumbly cover using a cotton swab, just to see if it helped.  The next day I realized that it increased the strength of the cover about 3X.  SOOOooo, I painted two coats on the new cover, front and back.  I took care in not filling screw holes or the connector slots.  It feels heavier now and much stronger!
That weekend it was all reassembled with great success.
It was sure nice to see it light up at night again and have all the idiot lights working!!
-Rob Young
1978 Pinto Pony sedan (Old Faithful) a.k.a. "the Tramp"
http://www.flickr.com/photos/thelonerider2005/sets
1972 Cutlass Supreme Convertible (442 clone) -"Lady" (My mistress...)
http://www.flickr.com/photos/robsalbum/sets
1986 Cutlass Supreme Coupe - "Pristine"
1997 H-D Sportster