RPO83

On Feb. 13, 1975, the automaker that created the van for American commerce, tradesmen and families expanded production of the Econoline, or E-Series, vans at a bigger, cleaner, more productive and technically advanced complex on the Lake Erie shoreline west of Cleveland.

Ford began in 1961 to build Econoline vans and later Club Wagons at its Lorain (Ohio) Assembly Plant. As sales blossomed, the company in 1972 bought a vacant plant in nearby Avon Lake and invested $100 million to combine the two into one the most advanced and flexible automotive assembly operations in the world.

Not only was it the industry’s first van, Ford’s E-Series is still the most versatile full-size van and the only one currently offering an optional diesel engine. And since 1979 the Econoline has been the best-selling full-size van in the U.S. for 24 straight years.

Knowing they were unable to anticipate all the varied demands of future Econoline customers—even in another industry segment created by Ford--those planners 30 years ago built maximum manufacturing flexibility into the Ohio Truck and Lorain Assembly plants. Tripling the previous range of choices, the E-Series plants were designed to build up to 476 different van and wagon body styles under flexible manufacturing options laid out in that long-ago renovation.

Scope, like versatility, is a hallmark of the two plants, which have nearly 4,000 employees and 8 million square of floor space combined. When the lines reopened in 1975, the body shops had dozens upon dozens of robot welders, and an elaborate complex of conveyors and feeder lines, tied together by 25 miles of wiring.

The paint shop design at the Ohio Truck Plant was especially innovative, with unique, glass-walled spray booths for better lighting and easier maintenance. At the end of each shift, enamel over-spray was easily rinsed away with a mix of vinegar and water.

With the energy crisis that emerged in the ’70s, Ford found another unique and efficient way to meet the two plants’ huge energy needs. The company opted to supply the plants with its own natural gas by developing gas fields in southeastern Ohio. With 30 wells pumping in almost 3.5 million cubic feet of gas a day, Ford used half the gas to run the plant and made the rest available to the public.

Ford’s 2003 E-Series models include the XL and XLT Wagons for a full range of family fun and functionality, plus a wider choice of commercial vans. The newest include the E-350/E-450/E-550 Super Duty Chassis Cab models, and an E-550 Super Duty Cutaway with five wheelbase options and GVW ratings from 17,000 to 19,500 lbs.

Econoline towing capacities range upward from 6,800 pounds for the E-150 with the 5.4L SOHC V-8 to 10,000 pounds for the E-350 Super Duty with the 7.3-Liter PowerStroke Turbodiesel. The 7.3L PowerStroke has just been named to Ward’s Auto World “Ten Best Engines” list for 2003, edging out its stable-mate 5.4L V-8, which was on Ward’s “Ten Best” list for six straight years.

The E-Series offers three more gasoline engines: a 4.2L V-6, a 4.6L V-8 and a 6.8L V-10, plus a compressed natural gas version of the 5.4L V-8

__________________
*Retired.