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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.

2020 Ford Police Interceptor Utility dominates Michigan State Police testing

The Michigan State Police has released its preliminary findings from testing the 2019 crop of police vehicles, and the results are a bit surprising. The consistent top performer of the bunch was the 2020 Ford Police Interceptor Utility, better known to civilians as the Ford Explorer. Specifically, the top performer was the model with the new turbocharged 3.0-liter V6. The Michigan State Police conducts acceleration, top speed, braking and lap time tests of all the available police vehicles. The 3.0-liter Police Interceptor Utility was the fastest to 60 mph at 5.77 seconds, had the highest top speed of 150 mph, and the best average lap time of 1:36.47. The lap time was particularly impressive as it was just over half a second faster than the next quickest car, the all-wheel-drive V8 Charger. View 13 Photos Still, the 2019 Dodge Charger gave the Explorer a serious run for its money. The all-wheel-drive V8 Charger was only 0.1 seconds behind the Explorer to 60 mph with a time of 5.87 seconds, and the rear-drive version was third quickest at 6.15 seconds. Both V8 Chargers were only 1 mph off of the Explorer's top speed, and the V6 example was third fastest at 141 mph. We already mentioned the all-wheel-drive V8 Charger was half a second off the Explorer's lap time, and the rear-drive variant was just over 1 second behind, giving it the third fastest average time. Dodge also took home braking bragging rights. The V6 Charger won out with a distance of 126.9 feet, followed by the rear-drive V8 Charger with 128 feet, and the V6 Durango Pursuit stopping at 128.8 feet. Now of course where there are winners, there are also losers. The slowest accelerating police car was the Ford Police Responder Hybrid Sedan, better known as the Fusion Hybrid, with a time of 9.24 seconds. At 8.59 seconds was the V6 Dodge Durango, and the V8 Chevy Tahoe with four-wheel-drive was third slowest at 7.98 seconds. Lowest top speed was 106 mph with the Ford F-150 Police Responder with the 3.5-liter turbocharged V6, followed by the V6 and V8 Durangos with 117- and 118-mph top speeds respectively. In braking, the Chevy Tahoes performed the worst with the rear-drive version stopping at 145.7 feet and the four-wheel-drive version stopping at 142.5 feet. The F-150 followed with 141.9 feet. When it came to lap times, the Fusion Hybrid lapped the slowest with a time of 1:46.31. The V6 Durango was about a second faster with a time of 1:45.45.

NHTSA advances investigation of Ford Crown Victoria headlights

The National Highway Traffic Safety Administration is opening a preliminary evaluation into reports of suddenly failing headlights on 517,945 examples of the 2003-2005 Ford Crown Victoria and Mercury Grand Marquis. The government started looking into this problem in April when the North Carolina Consumers Council filed a defect petition with the agency. Now, the inquiry has moved to the next step. According to NHTSA's documentation (as a PDF), it examined its own database and worked with Ford to come up with a total of 3,609 complaints of the front lighting control module suddenly failing. When this happens, drivers lose the low-beam headlights, but the high-beams can be used by holding the stalk. Sometimes turning the switch off and on fixes the issue. Additionally, there are 15 allegations of crashes, and one reported shoulder injury. NHTSA's preliminary evaluations "evaluate the scope, frequency, and consequence of the alleged defect" and don't necessarily lead to a recall. NHTSA looked into this problem once before in 2008 and 2009 and decided that a recall wasn't necessary. Ford also extended the warranty on the front lighting control module for these vehicles. INVESTIGATION Subject : Loss of headlights Date Investigation Opened: AUG 10, 2015 Date Investigation Closed: Open NHTSA Action Number: PE15028 Component(s): EXTERIOR LIGHTING All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD CROWN VICTORIA 2003-2005 MERCURY GRAND MARQUIS 2003-2005 Details Manufacturer: Ford Motor Company SUMMARY: After receiving a defect petition (DP15002) concerning the loss of headlights and other exterior lighting in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles, the Office of Defects Investigation (ODI) analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure. The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066). Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off. In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.