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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.

Ford EcoBoost successful because of Soviet laser weapons system expert?

Mike Kluzner is a man of many talents. Not only is he the software engineer responsible for fuel system diagnostics for Ford globally, he "got his start designing laser weapon systems capable of disabling the navigation systems of enemy satellites" for the former Soviet Union. Quite a résumé, wouldn't you say?
You may be asking yourself the same question that popped into our minds upon reading about Mr. Kluzner: What do laser weapon systems have to do with Ford and its EcoBoost engines? We'll let the man answer himself. "The same process for analyzing key physical relationships works for what we do today in engine combustion, catalyst chemistry and mechanics," says Kluzner. "These are all part of Ford's software engineering expertise." Who are we to argue?
Ford also employs an engineer who previously designed software to detect damage to the heat tiles on the International Space Station, as well as one who's past work involved particle physics, says the automaker in the press release below. David Bell (pictured above right), global boost system controls engineer for Ford, describes the software running EcoBoost as "the secret sauce" that makes the technology work as the driver intends and demands.

Ford F-150 Raptor gets EcoBoost V6, new chassis and aluminum body [w/videos]

The Autoblog staff universally loves the Ford F-150 SVT Raptor, and the truck's about to get even better. Coming in the fall of 2016 (we'd assume as a 2017 model), the next off-road-ready pickup from Ford will boast an all-new, purpose-built, high-strength steel frame and a lightweight aluminum body that saves more than 500 pounds when compared to the current Raptor. It's six inches wider overall than the regular 2015 F-150, which both makes it look awfully mean but also aids in stability when driving fast off the road, and new LED lighting elements make it stand out when the sun goes dim. Under the Raptor's muscular hood will be a 3.5-liter EcoBoost V6 engine that will make more than the current 6.2-liter V8's 411 horsepower and 434 pound-feet of torque, though we don't have exact power figures for the next-gen Raptor quite yet. Also new will be a 10-speed automatic transmission, which will replace the current six-speed unit and ought to provide appropriate ratios for both rock crawling and high-speed desert trail running. Speaking of high-speed running, what makes the Raptor tick, perhaps more than any other single component, are its custom-designed suspension bits. Redesigned, larger Fox Racing Shocks with more suspension travel and all-new terrain management technology, combined with BFGoodrich All-Terrain KO2 tires, are the bits and pieces that allow for Baja-style off-roading. View 14 Photos The four-wheel-drive system in the next-gen Raptor will include a Terrain Management with settings for Normal driving, Street driving, Weather mode (for rain, snow or ice), Mud and Sand, Baja mode and Rock mode. According to Ford, the Raptor's new transfer case is designed to work as both a locking unit for crawling and a full-time unit for other off-road applications. A Torsen front differential will be optional. Basically, if all of this new stuff turns out to be as good in practice as it sounds in a press release, the next F-150 Raptor will only serve to separate Ford's off-road pickup even further from its half-hearted competitors. Feel free to watch the video and read more down below.