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How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.

We test the 2016 Ford F-150 Pro Trailer Backup Assist

There are some automotive tasks that are more or less impossible the first time you attempt them, no matter your skill level. Remember the first time you had to back a trailer into position? Yeah, you'd have more luck disarming a nuclear bomb than getting the trailer where you're aiming. Ford is preparing to debut a technology that takes the mystery out of reversing a trailer, with the new Pro Trailer Backup Assist. Available on the entire 2016 F-150 range, the system essentially allows owners to drive their trailers by way of a dash-mounted knob. Turn the knob and the steering wheel automagically turns to the correct angle, leading the trailer in the desired direction. The steering wheel twirls about as needed, although drivers still have direct control of the accelerator and brake pedals, much as they do with Ford's Enhanced Active Park Assist system. Ford has spent eight years developing the system, the company's engineers told us. Drivers will need to measure their trailers a certain way and fit the checked reference sticker you can see in the gallery, although once a measurement is stored in the system, it can easily be recalled using the display in the instrument cluster. The system can stow the measurements for 10 trailers, and can accommodate tow-behinds up to 33 feet long. As of right now, though, the PTBA can't work with gooseneck trailers or fifth-wheels, although we're betting Ford is hard at work to accommodate those more substantial setups. "Pro Trailer Backup Assist is a smart solution to save time and increase productivity for our customers," Doug Scott, Ford Truck's marketing manager, said in the attached statement. "Instead of struggling to back up their trailer, they can spend more time on the job or enjoying the lake." We took part in a hands-on demo of the new system off the Detroit River, near Grosse Ile, MI. Full disclosure, we didn't back the trailer into the water, (your author had no interest in potentially damaging the roughly $50,000 boat/trailer Ford brought in for the test). We did, however, conduct a brief test in the safe confines of a nearby parking lot. Our immediate impression of this technology is that it will be a boon to novices or first-time towers, a group of which your author is a member. It takes the mystery out of backing up a trailer, and while there's still a learning curve involved, it's significantly easier than doing things the old-fashioned way.

Ford announces fix for 2021 Expedition and Lincoln Navigator fires

In the middle of May, Ford announced a recall of around 39,000 Ford Expeditions and Lincoln Navigators from the 2021 model year due to fires starting under the hoods of the SUVs. At the time, Ford had received 16 incident reports, 14 of them happening with rental vehicles. The automaker cautioned owners to park their vehicles outside and away from structures while engineers figured out what was happening and how to fix the problem. Since that May announcement, five more fires have been reported, four of them rental vehicles, and there's been one burn injury. The company announced it understands the problem and has a fix, at the same time widening the scope of potentially affected vehicles. Instead of recalling 39,013 units built between December 1, 2020, and April 30, 2021, the recall now includes 66,221 vehicles assembled from July 27, 2020, to Aug. 31, 2021. The suspected culprit is a circuit board provided by a supplier that changed manufacturing location during the pandemic. Ford's press release on the matter stated that "circuit boards produced at this facility are uniquely susceptible to a high-current short." The affected vehicles are fitted with either an 800-watt or 700-watt cooling fan system. About a third of the recalled population are fitted with the former, and should get a quick fix at the dealer. On these SUVs, techs will inspect the battery junction box. If they find evidence of melting, they'll replace the whole box. If not, they'll simply remove the engine fan ground wire that runs to the battery junction box; since this ground relay is redundant, the change doesn't alter operation of the fans.  Owners with the 700-watt system might need to wait until September for a fix. These vehicles need an auxiliary relay box with a wire jumper, but the parts aren't available now.   Ford's notifying all owners via the FordPass app, and will follow up with owners of the 700-watt cooling system once the parts are in stock. Until their vehicles are fixed, Ford says the SUVs are safe to drive but that they should still be parked outside and away from structures. The somewhat mixed messaging — 'Yes, your cars are safe to drive, but they could catch fire so don't park them near anything flammable' — encouraged a group of owners to file suit against Ford. Owners with questions can contact Ford customer service at 866-436-7332 and reference recall No. 22S36.