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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.

Ford profits soar as problems mount

Ford is doing well. It can't make enough examples of its new Fusion, it can barely make enough of the aging F-150, it's getting good brand rankings, people like its turnaround story, it's selling oodles of product and its quarterly profit numbers end in the word "billion." As other high-flying examples have demonstrated over the past few years, though, big numbers can come with problems that aren't exactly small.
Automotive News has published a good "nutshell" report of Ford's progress and problems. The Dearborn automaker's optimistic "general label rule" determination of gas mileage for the C-Max Hybrid has led to lawsuits, hybrid software updates, a downward revision of C-Max fuel economy and millions in rebates. AN notes the C-Max was the "worst-scoring model in this year's J.D. Power Initial Quality Study," but Ford will probably be happy that it managed not to be mentioned further in the study's results after last year's mediocre showing. Its MyTouch and SYNC systems, the bugbears sabotaging Ford's J.D. Power results, have also led to lawsuits, software updates, more software updates and a center console rethink. On top of that, the 1.6-liter EcoBoost in the 2013 Ford Escape that Ford called a "hero" was soon catching fire for three different reasons. And let's not even get into the troubled launch of the Lincoln MKZ.
The Automotive News piece notes that industry observers have been surprised at Ford's stumbles because everything has been looking so good. Nevertheless, there is still the issue of those billions in profits - the company is doing plenty of things, plural, right. Ford says it is tackling its problems, hiring engineers and instituting new quality control processes as part of its effort to find solutions. The test will be to see if in a year from now we begin the discussion of these issues with "Remember when Ford...", or "Problems continue at The Blue Oval."

How tariffs in China could cause a meltdown in the American South

While BMW is clearly a German company, the crossovers that are exceedingly important to it are actually made in Spartanburg, South Carolina. And more than that, the Spartanburg plant (physically located in the town of Greer) is where the corporate know-how and capability for those vehicles is concentrated. These are the vehicles – specifically, the BMW X3, X4, X5, X6, X7 – that drove record growth for the company in 2018, according to BMW. But whatÂ’s most notable about BMW Group Plant Spartanburg, given current events, is that according to the U.S. Department of Commerce it was the largest automotive exporter by value for the fifth year running in 2018. ThatÂ’s worth emphasizing: largest automotive exporter by value. Not GM. Not Ford. BMW. And where might one assume that more than a few of those X vehicles are shipped to? China. Some 360 miles southwest of Spartanburg is Mercedes-Benz U.S. International, Inc., in in Tuscaloosa County, Alabama. It started building vehicles in 1997. Since then, Daimler AG has invested in excess of $5.5 billion in the facility. It manufactures the crossover now known as the GLE, formerly the ML-Class. It also makes the GLE coupe and GLS. Daimler describes the Tuscaloosa facility as “the traditional home of SUV production” for those vehicles. When it reported its global 2018 sales, Daimler noted that on a global basis SUVs account “for more than a third of all Mercedes-Benz sales.” According to the Chinese finance ministry, on December 15th the Chinese government will impose a 25% tariff on automobiles (and a 5% tariff on auto parts) from the U.S. Certainly this is going to have a direct effect on the sales of vehicles that are manufactured in the U.S. and exported to China. BMW and Mercedes are going to take it on the chin for the vehicles that they make in plants that they invested in so heavily in the U.S. Which could potentially mean that people in places like Greer, South Carolina, and Vance, Alabama, are going to find themselves in the crosshairs of the combatants. Soo too could Lincoln, which produces vehicles in places like Louisville, Kentucky (Navigator), Chicago, Illinois (Aviator) and Flat Rock, Michigan (Continental). Although the Tesla Gigafactory 3 is rapidly nearing completion in Shanghai, it is worth noting that vehicles built in Fremont, California, are being sold in China in numbers that donÂ’t make Musk unhappy.