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Ford Explorer problems gutted third-quarter sales

In early September, the Detroit Free Press published a feature noting numerous problems Ford's having with the 2020 Explorer and 2020 Lincoln Aviator launches. Issues with both SUVs, built at Ford's Chicago Assembly Plant, were so rife and dire that the automaker was trucking the vehicles 275 miles away to Michigan for repairs. Bloomberg reported earlier this month that Explorer's third-quarter sales dropped 48 percent compared to the previous model in 2018, with dealers unable to get enough units on lots for customers. Nor is the snafu over: Automotive News reports that another "batch of about 2,500 Explorers in need of repairs" arrived recently in Michigan, and sales through the first nine months of 2019 are down 31 percent. Sales dips during model changeovers are to be expected as old inventory gets sold down and new production ramps up, but this is different. Ford U.S. sales boss Mark LaNeve told Bloomberg earlier this month, "We’ve got adequate inventory in our stores. For Q4, availability wonÂ’t be an issue. WeÂ’ll be able to hit our stride with Explorer starting now." It's hard to know whether that's true, with thousands of Explorers still piling into Michigan; the batch AN mentioned represents about 5 days of sales during an average month in 2018, before the drawdown and interruptions hampered matters. And when Consumer Reports tested the Ford Explorer it bought this summer, it titled the review, "2020 Ford Explorer drives nicely but has many flaws / Poor interior quality and a high price overshadow the SUV's improvements."   On top of that, the AN piece mentions a new impediment to uncorking the Explorer sales stream: Worker strife in the Chicago plant. Allegedly, "Roving groups of workers are intimidating other employees, creating a hostile environment, the people said. ThatÂ’s driving up turnover and leaving some vehicle assembly unfinished, contributing to the company having to complete the work at the Michigan factory or at dealerships, the people said." Ford's been fined twice before for the same kinds of issues at its plants, once in 1999, again in 2017, but a spokesperson said Ford isn't aware of any such problems now. The pressure otherwise has got to be unpleasant for everyone on the Explorer team, from CEO Jim Hackett down. The automaker was meant to be "turning the corner" in April, but as of now, shares are down, credit rating is down, earnings are down.

What an Atlas-based Ford F-150 might look like

Just ahead of January's Detroit Auto Show, surprising rumors pegged Ford as revealing some sort of F-150 concept, perhaps as a hurried effort to deflate some of the buzz building around General Motors' new Chevrolet Silverado and GMC Sierra twins, which were also making their auto show debut. Those rumblings turned out to be true, as Ford rolled into the Motor City with its Atlas concept (inset, right), touting the truck's bold styling as a precursor to the next-generation F-Series.
The show truck featured all kinds of clever details, including active wheel shutters and a front air dam that raised and lowered to improve aerodynamics while preserving off-road ability. It also had a genuinely snarly face. And it's that pugnacious snout that may well be on its way to production. The good folks at TopSpeed have worked up the plausible-looking artist's rendering above by cross-referencing the Atlas concept with what little has been revealed from recent spy shots. The look is toned-down pretty dramatically from the concept truck, but its Atlas roots are clear, with a massive three-bar grille and bracket-shaped headlamps hiding a next-generation EcoBoost engine. In the rendering, the show truck's deeply contoured hood and roofline have been ditched and larger, more traditional side mirrors have been fitted - all likely concessions in the move to production sheetmetal.
While Ford has yet to officially announce when it will unveil the 2015 F-150, all signs point to next year's Detroit Auto Show - one year after the Atlas shrugged off GM's new pickups.

Ford recalls 90,736 vehicles due to engine valve issue

Ford will recall 90,736 vehicles as engine intake valves in the vehicles may break while driving, the National Highway Traffic Safety Administration (NHTSA) said on Saturday. The recall impacts certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine, the NHTSA said. According to documents posted by NHTSA and sourced from the automaker, "The engine intake valves may break while driving, which can result in engine failure and a loss of drive power." Following an investigation that started in January, 2022, Ford found 22 instances where "the engine intake valves fractured and fell into the combustion chamber of the engine causing catastrophic engine damage." The automaker's analysis continues: "Ford identified that the potential root cause of the failures was engine intake valve failure due to valves that exceeded the designed specification for hardness, were brittle, and more likely to fracture. Ford determined that this was due to the supplier’s grinding processes and the sensitivity of the intake valve material to grinding processes that were not within control specifications. The intake valve material was changed for vehicles produced after October 31, 2021." Fixing the problem will require replacement of the entire engine. "Dealers will inspect each vehicle to determine its cumulative number of engine cycles. For vehicles that do not meet the engine cycle threshold, dealers will accumulate high revolutions per minute (rpm) engine cycles per a service procedure. Engines will be replaced on vehicles that do not pass the engine cycle accumulation," Ford says.