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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

Porsche Taycan 4S, Ferrari Roma and a tuned Ford Ranger | Autoblog Podcast #624

In this week's Autoblog Podcast, Editor-in-Chief Greg Migliore is joined by Consumer Editor Jeremy Korzeniewski and Senior Editor, Green, John Beltz Snyder to recap Earth Day 2020 coverage, including a first drive and range test of the 2020 Porsche Taycan 4S, Tesla and the state of the EV industry, and what we think are the best green cars of all time. Then they shift gears to talk about the Ranger pickup getting a tuning package from Ford, as well as their own dives through the Ferrari Roma configurator. They discuss the cars they've been driving — the 2020 VW Jetta and our long-term 2019 Subaru Forester. Lastly, they reach into the mailbag to help a listener buy a used car. Autoblog Podcast #624 Get The Podcast iTunes – Subscribe to the Autoblog Podcast in iTunes RSS – Add the Autoblog Podcast feed to your RSS aggregator MP3 – Download the MP3 directly Rundown Earth Day recap 2020 Porsche Taycan 4S Tesla and the EV industry The best green cars of all time Ranger gets a tuning package from Ford Configuring the Ferrari Roma Cars we're driving 2020 Volkswagen Jetta 2019 Subaru Forester long-term update Spend My Money Feedback Email – Podcast@Autoblog.com Review the show on iTunes Related Video:

Ford Ranger-based 7-seat SUV spotted testing

Ford looks to be working on a new SUV version of its global Ranger pickup truck. An early prototype of a seven-passenger SUV based on the Ranger has been spotted testing in Australia, and word has it buyers in the region could expect to see the model in showrooms as soon as 2014, where it could sail under the Endeavour or Everest badges. Ford Australia currently sells the Territory SUV, so there's some chance that this model could be a successor to that throne, as well.
Whatever it's called, the long-roof Ranger will feature a shorter wheelbase and more ground clearance than its pickup twin, giving the machine a bit more off-road functionality. (And here we thought we couldn't want the global Ranger any more than we already do.) While this particular vehicle sports a Territory back half grafted onto a Ranger front end, odds are a public reveal of the finished product could occur as soon as the second half of 2014, making it a 2015 model. Head over to Carsguide.com.au for a closer look.