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2013-2017 Ford Explorer recalled over rear suspension issue, again

Ford is recalling about 375,000 Explorer SUV models built between 2013 and 2017 in North America to fix a potential defect in the rear suspension. In "North America states and provinces where corrosion is common," which we take to mean areas that experience harsh winters and heavily salted roads, "a fracture of the outboard section of the rear suspension toe link" is possible on affected vehicles. Ford says 350,000 of these models were sold in the United States and another 25,200 in Canada. This isn't the first time Explorers of this generation have been recalled for fractured toe links. Back in the summer of 2017, 1.2 million Explorer models were recalled over toe links that could fracture if subjected to "frequent full rear suspension articulation (jounce and rebound)." A little over a year earlier, 75,000 Explorers were recalled over, you guessed it, rear toe links that may not have been welded properly. It's not just Explorers that Ford has recalled over rear toe links. Earlier this year, the automaker issued a recall that covered nearly 230,000 Ford Flex, Taurus and Lincoln MKT models. All of these recalled vehicles ride on similar unibody underpinnings that Ford calls the D4 platform. We can't say whether these other D4-based vehicles will get another recall as the Explorer has. Ford says it is aware of as many as 13 crashes and six injuries attributable to the toe links covered under this most recent Explorer recall. Owners will need to visit their preferred dealership, which will "complete a torque inspection of the cross-axis ball joint and replace it as necessary," according to Ford. Related Video:

Aluminum lightweighting does, in fact, save fuel

When the best-selling US truck sheds the equivalent weight of three football fullbacks by shifting to aluminum, folks start paying attention. Oak Ridge National Laboratory took a closer look at whether the reduced fuel consumption from a lighter aluminum body makes up for the fact that producing aluminum is far more energy intensive than steel. And the results of the study are pretty encouraging. In a nutshell, the energy needed to produce a vehicle's raw materials accounts for about 10 percent of a typical vehicle's carbon footprint during its total lifecycle, and that number is up from six percent because of advancements in fuel economy (fuel use is down to about 68 percent of total emissions from about 75 percent). Still, even with that higher material-extraction share, the fuel-efficiency gains from aluminum compared to steel will offset the additional vehicle-extraction energy in just 12,000 miles of driving, according to the study. That means that, from an environmental standpoint, aluminum vehicles are playing with the house's money after just one year on the road. Aluminum-sheet construction got topical real quickly earlier this year when Ford said the 2015 F-150 pickup truck would go to a 93-percent aluminum body construction. In addition to aluminum being less corrosive than steel, that change caused the F-150 to shed 700 pounds from its curb weight. And it looks like the Explorer and Expedition SUVs may go on an aluminum diet next. Take a look at SAE International's synopsis of the Oak Ridge Lab's study below. Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO2e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production ("Baseline"), an advanced high strength steel and aluminum design ("LWSV"), and an aluminum-intensive design (AIV).

Ford sets world record for biggest Hot Wheels track loop

Take Your Child to Work Day looks like a pretty amazing experience for a child if their parent works at Ford. For the recent event, workers at the Blue Oval set up the world's largest Hot Wheels track loop in the atrium of the company's Research and Innovation Center in Dearborn, MI, and launched toy cars from over three stories. The idea came from Ford dynamometer technician Matt West who had been building progressively larger loops with his son. This one was the biggest ever, though, with a ramp 35.5-feet high and a 12.5-foot loop to crush the previous record of nine feet, nine inches tall. Fittingly, the track was inaugurated with a Ford Mustang Hot Wheels car taking the first run. To support such a massive size, the Hot Wheels track fits into a plywood structure that's bolted together. Beyond just being fun and looking incredibly cool, the stunt was meant to teach kids about mathematics and engineering. Ford Sets World Record for Biggest Hot Wheels Car Track Loop in Support of Take Your Child to Work Day • To help children cultivate an interest in science and engineering, Ford attempted to set a new world record for building the largest Hot Wheels® car track loop as part of this year's Take Your Child to Work Day • Ford Mustang Hot Wheels car started at more than three stories high inside Ford Research and Innovation Center • Old record loop stood at nine feet, nine inches tall DEARBORN, Mich., April 23, 2015 – Ford ran circles around the old Hot Wheels® record loop as part of this year's Take Your Child to Work Day. When the effort was complete, Ford had made a world record attempt with a Hot Wheels car track loop that exceeded 12 feet tall. The world record attempt was the brainchild of Ford dynamometer technician Matt West, who had built increasingly large Hot Wheels loops with his six-year-old son Blade at their home in Monroe, Michigan. The attempt took place in the three-story atrium of the company's Research and Innovation Center in Dearborn in support of Ford's participation in national Take Your Child to Work Day. "It started as part-fun, part-physics lesson with my son at home," said West. "We built one in our playroom, and then built a five-foot- tall loop in our backyard.