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Ford recalls Five Hundred, Mercury Montego sedans over fuel tank woes

Ford has announced through the National Highway Traffic Safety Administration that it is recalling nearly 3,000 examples of its Five Hundred and Mercury Montego (pictured) sedans from the 2007 model year.
The action, which affects 2,945 vehicles, is due to potentially defective welds between the filler neck and the fuel tank, a condition that could result in a fuel leak or the smell of gasoline reaching the occupants. In the worst-case scenario, a leak could cause a fire. Cars with the affected fuel tank problem could see an illuminated dashboard warning light as a result of the evaporative emissions leak being detected.
Ford will inspect and replace the fuel tank at no cost to owners (those who have already had the procedure done at-cost can apply for reimbursement), and the Dearborn automaker will begin notifying Five Hundred and Montego owners beginning August 15. Check out the official NHTSA press release after the jump for further details.

Ford Focus ST checks into Jay Leno's Garage

In a change of pace from the high-end vehicles that often appear in Jay Leno's Garage, Ford sends its hottest hatchback (in the US, at least), the 252-horsepower Focus ST, to be featured on Leno's show. Accompanying the five-door hatch is its chief engineer, Jamal Hameedi.
Riding on stylish 18-inch wheels with summer tires and with a spoiler that doubles as a lunch tray, Hameedi and Leno walk us through the finer points of what makes the ST special, which also includes bigger brakes, torque vectoring, a manual transmission and, of course, 252 hp and 270 pound-feet of torque from the 2.0-liter EcoBoost four-cylinder engine, which is made possible by 21 psi of turbocharged boost.
Watch the video below to see what Leno thinks of the global Focus ST.

Ford reveals new rapid prototyping and low-volume production techniques [w/video]

It's called "F3T," and that stands for Ford Free-form Fabrication Technology. The process that The Blue Oval has developed means being able to sidestep the weeks-long process of tool-and-die making when engineers want to construct a new part, allowing them to fabricate a three-dimensional part from a two-dimensional sheet of metal in just hours.
While F3T is being developed it is limited to "low-volume prototyping or even low-volume niche vehicles," but the next step is to evaluate it for use in Ford's global manufacturing facilities. You can find out more about it in the video and the press release below.