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2020 Ford Explorer, Lincoln Aviator reportedly facing numerous QC issues

A lengthy report in the Detroit Free Press delves into a range of quality control issues confronting the 2020 Ford Explorer and its luxury platform sibling, the 2020 Lincoln Aviator. Freep says it's been following the issue for two months, tapping various unnamed sources for information on the automaker's unorthodox route to resolution. Seems the problem is Explorers and Aviators leaving the production line at the Chicago Assembly Plant with flaws in areas like the chassis, transmission and suspension, said vehicles trucked to Ford's Flat Rock Assembly Plant (FRAP) outside of Detroit for repair. The estimates range from 10,000 to 18,000 vehicles affected, numbers so high that Ford has sought help from Roush Engineering in nearby Allen Park, and brought workers and managers from other plants in the Midwest to FRAP to get vehicles repaired and shipped to dealers. Ford hasn't shared the nature of the problems with anyone outside the company, including dealers and customers. Freep's sources are said to include workers who have provided photos of certain vehicles and of tents used to house parts at the FRAP repair site. The Explorer chassis allegedly has an unidentified problem that engineers are using X-rays to diagnose, and the transmission is having problems sensing when it's in park or going into park. Both the Explorer and Aviator have come off the line with HVAC units that only blow hot air. And the Aviator's height-adjustable suspension enters failure mode for unknown reasons. These come on top of quotidian mishaps common to every new vehicle, but that are meant to be sorted in pre-production, like missing emblems and trim pieces. They also come on top of a recall in early August issued for the Explorer and Aviator concerning the instrument cluster and parking brake, and another at the end of August over rear seatbacks that could collapse in a crash. An automaker spokesperson told Freep, "Making updates to preproduction models based on all-new platforms as they roll off the assembly line – is standard industry practice." Except these aren't pre-production, these are early production vehicles that paying customers and dealers are waiting for, and some of the affected vehicles have been pulled off dealer lots. Dealers say they are fine waiting for the trucks to get sorted out, and they'd rather have Ford fix the problems before the SUVs go to customers.

How Ford's light lab keeps the sun shining on the new Mustang just right [w/video]

Anyone who's bought one of those old school metal shift knobs knows they're really cool until they sit in a parking lot in the sun for a few hours. Then they're not cool at all. Likewise, features such as the aluminum dash on the 2015 Ford Mustang can be all kinds of neat right up until the sun hits it just the right way and sends shards of blinding light through the cabin. The Ford Visual Performance and Evaluation Lab is where engineers figure out how to make sure that doesn't happen.
Cars like said Mustang are parked inside the 30-foot reflecting dome under 6,000 watts of lights that can mimic the sun at any time of day and in any weather condition. Engineers can then spend cold, overcast days inside, testing for interior legibility, glare and reflections on every interior and exterior surface as if it were bright and sunny. They can also learn how a car's sheetmetal and colors will look out of doors, all year round.
Ford showed off the lighting lab without the music and interviews three years ago when the Explorer was being prepared. You can watch it at work again in the video below, and read about it in the press release below that.

Ford Focus PHEV on the way?

A refreshed Ford Focus is in the works and that means a few details are leaking out. Spy shots from last month indicated the Focus will have a gaping grille just like its "One Ford" global C-segment comrade, the Fiesta. While Ford is being quiet about it, the Focus could also be getting an "Energi" option, joining the C-Max Energi and Fusion Energi in Ford's plug-in hybrid family. The Focus will likely use technology originated in the C-Max Energi that combines a 2.0-liter gasoline engine with an electric motor capable of a 20-mile range, according to Autoexpress. The pure electric Focus is expected to stay in the lineup despite its slow sales; its price range should be similar to what's on the market now. The third-generation Focus looked good enough to become the top-selling nameplate in the world in 2012. Some exterior changes to look for in the Euro-spec model at the Geneva Motor Show in March include a reshaped hood, front wing endplate and rear bumper. Interior spy shots have hinted at an updated dashboard design and a simplified, less cluttered control panel with updated climate controls. Under the hood, there are quite a few power options rumored to be available - a gasoline EcoBoost with up to 123 horsepower and two turbo-diesel TDCI options, a 1.6-liter or 2.0-liter mills that would produce between 94 hp and 161 hp. Then there are new 1.5-liter diesel and 1.5-liter EcoBoost gasoline variants that meet regulations in China, Brazil and Russia.