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NHTSA opens investigation into Ford Explorer PI brakes

This year more than most, it's pleasant when we can string together a few days without word of an automaker or the National Highway Traffic Safety Administration announcing a bunch of new recalls. It's seemingly been a little quiet on this front lately (barring a spider-related Suzuki issue revealed early today), but now we have word of the government safety agency opening a Preliminary Evaluation into the 2013 Ford Explorer Police Interceptor, a probe that could potentially affect an estimated 20,000 vehicles.
The issue being investigated concerns failures of the front brake hose on the vehicle that show "small splits in the hoses near the body side ferrule of the hose assembly," according to the agency, and the issue could result in longer stopping distances. The feds have reports of 13 malfunctions affecting 11 Explorer units. However, it's important to note that all of the incidents come from a single, unnamed metropolitan police fleet that operates 46 of them. According to The Detroit News, the failures generally took place between December and July.
NHTSA is investigating further to find if this is a more widespread issue than just this one fleet. Ford spokesperson Kelli Felker confirmed to us, "We are cooperating with NHTSA on this investigation, as we always do." Scroll down to read the agency's report.

Ford cleans up painting process with cameras

Knowing how the bacon gets made rarely entices us and, in the same vein, the same usually goes for knowing about how new cars get painted. But in both instances, however, quality - or a lack thereof - is instantly obvious. In terms of the latter, Ford is showing off its new paint quality process with 3D Dirt Detection Technology to find imperfections in vehicle paint more easily and more quickly.
This process - being performed on the F-150 SVT Raptor above - uses 16 computer-controlled cameras to create a three-dimensional model (inset) of the vehicle to detect flaws in the paint including dirt particles, which can then be buffed out manually. Ford says this new technology cuts down on time spent looking for paint flaws and gives workers more time to correct those that are discovered.
Currently, Ford only uses its 3D Dirt Detection Technology system at three factories (the Dearborn, MI facility, along with those in Louisville, Kentucky and Valencia, Spain), but it will soon spread to five more plants in North America. Ford has released a video and press release for this innovative and unexpectedly interesting process, both of which are posted below.

EarthCruiser adds a bigger camper option to its heavy duty pickup line

EarthCruiser is a camper and expedition vehicle company based out of Oregon that we've previously covered for its huge commercial truck-based machines. But they offer more than that, from drop-in campers for smaller pickups to heavy duty pickup conversions. The company's latest product is one of the latter, offering a larger camping area than the current EXD model. This new camper conversion is called the Terranova. The big differentiator between it and the EXD is the camper section, which extends over the truck cab on the Terranova. This means that bed space can be moved to above the truck cab, instead of having to use a convertible dinette. So less reconfiguring, and generally more usable space. One other major difference is that the EXD is only available for the Ram 3500 and Ford F-350. The Terranova is being designed for both of those trucks as well as the Chevy Silverado 3500. The EarthCruiser Terranova is otherwise very similar to other EarthCruiser models. The camper section is made of fiberglass and plastic, and the pop-up roof is insulated with foam. The curtains are triple-layered. The company says it can house four people. It comes with a freshwater tank and pump to help supply the kitchen sink, drinking water tap, bathroom sink and indoor and outdoor showers. There's also a cassette toilet. The kitchen features an induction stove top and small refrigerator and freezer. A fan system is standard, and air conditioning is optional. Power comes from a 400-aH lithium-ion battery. The Terranova isn't yet available. EarthCruiser is finishing up design and engineering, and it plans to have finished examples early next year. The company is taking reservations now, though. Pricing hasn't been announced, but an EXD runs between $220,000 and $265,000, and we would expect the Terranova to cost even more. Related Video: Featured Gallery EarthCruiser Terranova Expedition Camper renderings Chevrolet Ford RAM Truck Off-Road Vehicles Special and Limited Editions RVs/Campers