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Ford recalls over 680,000 Ford Fusions, Mondeos, and Lincoln MKZs for seat belt pretensioners

Update: We spoke with a Ford representative who said that owners will be notified by mail during the week of January 16 . Dealers will also have the fix available at the same time. Owners can bring in their vehicles to dealers for an evaluation in the mean time. The main text has been updated to reflect this. The Basics: Ford is recalling 680,872 2013-2016 Ford Fusions, 2015-2016 Ford Mondeos, and 2013-2015 Lincoln MKZ s for an issue with front driver-side and passenger-side seat belt pretensioners. The Problem: The seat-belt pretensioners did not have sufficient insulation applied. When the pretensioners are activated, the heat generated can cause the cables connected to the belts to separate, which in turn can prevent the seat belts from effectively restraining the occupant. This can lead to injuries. Injuries/Deaths: Ford reports two accidents and two injuries have occurred that are related to this recall. The fix: A dealer technician will inject an insulation coating around the pretensioner. This should effectively keep the heat away from the cables, ensuring the seat belt will properly restrain the user in a collision. If you own one: Affected owners will be notified by mail on the week of January 16. Dealers will have the fix available that week, and owners will be able to bring in their vehicles for the fix to be implemented free of charge. Related Video:

Aluminum lightweighting does, in fact, save fuel

When the best-selling US truck sheds the equivalent weight of three football fullbacks by shifting to aluminum, folks start paying attention. Oak Ridge National Laboratory took a closer look at whether the reduced fuel consumption from a lighter aluminum body makes up for the fact that producing aluminum is far more energy intensive than steel. And the results of the study are pretty encouraging. In a nutshell, the energy needed to produce a vehicle's raw materials accounts for about 10 percent of a typical vehicle's carbon footprint during its total lifecycle, and that number is up from six percent because of advancements in fuel economy (fuel use is down to about 68 percent of total emissions from about 75 percent). Still, even with that higher material-extraction share, the fuel-efficiency gains from aluminum compared to steel will offset the additional vehicle-extraction energy in just 12,000 miles of driving, according to the study. That means that, from an environmental standpoint, aluminum vehicles are playing with the house's money after just one year on the road. Aluminum-sheet construction got topical real quickly earlier this year when Ford said the 2015 F-150 pickup truck would go to a 93-percent aluminum body construction. In addition to aluminum being less corrosive than steel, that change caused the F-150 to shed 700 pounds from its curb weight. And it looks like the Explorer and Expedition SUVs may go on an aluminum diet next. Take a look at SAE International's synopsis of the Oak Ridge Lab's study below. Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO2e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production ("Baseline"), an advanced high strength steel and aluminum design ("LWSV"), and an aluminum-intensive design (AIV).

Ford F-150 production hampered by frame shortage

If anyone has questions about how Ford's new aluminum-bodied F-150 will hold up, it's not buyers. Orders are so strong for the fullsize pickup that competitors General Motors and Ram are discounting their offerings to hold onto market share. It's a shame for the Blue Oval then, that it can't build all the trucks it needs because frame supplier Metalsa isn't delivering enough frames. Neither Ford nor Metalsa has said what the problem is, but Ford employees are at Metalsa's Kentucky plant trying to get it sorted out, Automotive News reports. Overtime shifts at the Dearborn Truck Plant and the Kansas City Assembly Plant have been canceled due to the shortage that's been a problem for at least two months now. The issue is exacerbated by this being the changeover period in production from the old model to the new, which comes with its own issues. That would help explain why even though Dearborn production finished ramping up in January, output in April was down 9.2 percent compared to last year, according to AN. Transaction prices are up for the new truck, but overall F-150 production in Q1 was down 40 percent, and missing product means missing profits. Combined with the production drop for the new Ford Edge, the company's Q1 bottom line was robbed of $1 billion. It isn't clear when the frame issue will be solved, but workers at the plants are ready to run "all-out" when it is. Related Video: News Source: Automotive News - sub. req.Image Credit: Copyright 2015 Drew Phillips / AOL Plants/Manufacturing Ford Truck kansas city assembly plant