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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.

Automakers, dealers are rushing cars to Houston after Harvey

DETROIT — Houston-area car retailers and automakers are rushing to reopen dealerships and beef up inventory to replace many hundreds of thousands of vehicles damaged in flooding from Hurricane Harvey. Pete DeLongchamps, vice president for manufacturer relations at Group 1 Automotive, the third-largest U.S. auto dealer group, said the company prepared for the storm with a plan designed after Hurricane Katrina in 2005. This included moving moved inventory to higher ground and cleaning roof drains to avoid cave-ins. Group 1 thus lost a "relatively small percentage" of inventory and reopened its roughly 25 dealerships in the Houston and Beaumont area by Thursday. "Things have been moving fast and furious with a large number of tow-ins already," DeLongchamps said. "Our customers have lost a lot of vehicles, we need to help them replace." Harvey brought record flooding to Houston and killed at least 35 people. The storm is expected to briefly depress already slowing U.S. auto sales but could eventually help boost demand as damaged cars are replaced. Automakers report U.S. August sales on Friday. Estimates for the number of Harvey-damaged vehicles needing replacement range up to 500,000. By Thursday, AutoNation, the largest U.S. auto retail chain, had reopened its 17 Houston stores and is moving cars and trucks from other regions, company spokesman Marc Cannon said. The company plans to move 500 to 1,000 used cars to an AutoNation USA used car store and stage a sale Sept. 21-23, when many would-be buyers should have insurance checks to replace destroyed vehicles, Cannon said. AutoNation is still assessing how many vehicles it lost, but it too moved vehicles to higher ground ahead of the storm. General Motors spokesman Jim Cain said the number of damaged vehicles at dealerships "is relatively modest." "But there are still several dealerships that are inaccessible, so the number will increase," he said. GM will move new and used vehicles to Houston, "but it won't be done until the infrastructure and our dealers are ready." Ford is still assessing damage and inventory needs, a spokeswoman said. CarMax, the biggest U.S. used car dealer, will reopen its six Houston area stores on Labor Day, spokeswoman Claire Hunter said. "We are mobilizing additional inventory to the region as we speak," Hunter said. Paul Lips, chief operating officer at ADESA, a unit of KAR Auction Services Inc., which with Manheim dominates the U.S.

Ford and Lincoln recall about 170,000 vehicles over defective rear-view camera

Ford and Lincoln have jointly issued a safety recall that includes nearly 170,000 vans and SUVs built between the 2018 and 2023 model years. The vehicles included in the campaign are equipped with a rear-view camera whose image can cut out while the driver is backing up. Assigned recall number 23V-598 by the National Highway Traffic Safety Administration (NHTSA), the campaign includes the following cars: 7,649 units of the 2020-2023 Aviator fitted with the standard rear-view camera and built from October 19, 2019, to August 17, 2023. 70,600 units of the 2018-2021 Navigator fitted with the 360-degree camera and built from March 16, 2017, to December 23, 2021. 66,740 units of the 2022-2023 Transit fitted with either camera system and built from February 26, 2021, to August 17, 2023. 24,468 units of the 2021 Bronco fitted with the 360-degree camera and built from September 23, 2020, to December 22, 2021. Ford explains that the defect is present in all of the 169,277 vehicles included in the campaign. While these are different cars equipped with different technology, they all suffer from the same problem. The company explains that "customers may intermittently experience either a rear camera blue image or a full blue or black image on the SYNC [infotainment system] screen when the vehicle is placed in reverse, or when the 360-degree view is selected and available." It adds that losing the camera's image while backing up increases the risk of the crash. The cause of the problem varies from model to model. Ford has narrowed it down to the camera hardware, the wiring retention, and the Image Processing Module - V (IPMB) software. It adds that "fretting corrosion causes tin oxide formation on the internal camera connector due to [a] thermally-induced micro-movement between the tin-plated contact surfaces," and that the rate of tin oxide accumulation depends on factors such as the temperature and the humidity. It has also traced some of these issues to a problem during the manufacturing process. Ford will begin notifying owners of affected vehicles by mail on October 2. When parts are available, owners will be asked to bring their van or SUV to an authorized dealer so that a technician can replace the rear-view camera. Transit models included in the campaign will also receive a software update. Owners who have already paid to fix the problem can claim a reimbursement until June 30, 2024. This isn't Ford's first rear-view camera-related recall.