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Hot-selling Ford Expedition, Lincoln Navigator get production boost

Ford is investing an additional $25 million in its Kentucky Truck Plant in Louisville to increase by 25 percent production of the hot-selling and all-new Lincoln Navigator and Ford Expedition SUVs. The investment adds to $900 million in previously announced spending at the plant, which also builds F-Series Super-Duty pickups and employs 8,400 workers. Assembly-line workers are putting in overtime and working voluntary weekend shifts to keep up with demand. The new investment will cover upgrades to the assembly line but does not involve further hiring, Ford spokeswoman Kelli Felker says. The popularity of the Ford Expedition and Lincoln Navigator is a bright spot as Ford stock has been battered by Wall Street amid concerns concerns about the automaker's future vision and slowness to detect trends. Ford says the investment is an example of its bid to improve "operational fitness," one of CEO Jim Hackett's common refrains. Ford says Navigator retail sales more than doubled in January, and Navigators are spending an average of just seven days on Lincoln dealership lots as customers trade in vehicles including Land Rovers and Mercedes-Benz. Nearly 85 percent of buyers are opting for high-end Black Label and Reserve trim packages, contributing to an average transaction price increase of more than $21,000 in January compared to a year ago. The 2018 Navigator won the North American Truck of the Year award and also topped a Detroit News poll of public favorites at last month's Detroit Auto Show. Sales of the Expedition, meanwhile, were up almost 57 percent last month as the full-size SUVs also spent an average of just a week on dealer lots. Platinum trim models represented 29 percent of sales, pushing transaction price increases up $7,800. Ford gave the 2018 Expedition an all-aluminum body to save mass in its first significant redesign since 2007. The plant last year got nearly 400 new robots, mainly in the body shop, to help increase line speed, and Ford added a robot lab where employees can test software tweaks or troubleshoot issues away from the factory floor. The Louisville plant also benefits from extensive new data analytics, with seven big-screen monitors providing minute-by-minute updates showing progress against hourly targets or alerting workers to pending parts shortages. A huge spare-parts "vending machine" lets workers more quickly locate needed parts and keep inventory at necessary levels.

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 and Lincoln recall roundup: Explorer, F-350 Super Duty, Aviator

Ford and Lincoln released information on a flurry of recalls this morning. There are three in total, and they span different models and separate issues. Those models include the 2013-17 Ford Explorer, 2020-21 Lincoln Aviator and 2020-21 Ford F-350 Super Duty. We’ll organize these three in order of most cars recalled. 2013-17 Ford Explorer This recall includes a substantial 774,696 vehicles, of which 676,152 are in North America. Why? Ford says these vehicles “may experience a seized cross-axis ball joint that may cause a fractured rear suspension toe link.” The diminished steering control that would follow could increase the likelihood of a crash, Ford states. Only vehicles that spent time in high corrosion states should be affected, Ford says. That means places that lay salt down, experience cold weather and high humidity. Owners of these vehicles will need to take their car into the dealership, where it will be inspected to determine if it needs work. If so, Ford will replace the cross-axis ball joint/knuckle, then replace the toe links with a newly-designed part. Notifications to owners of these vehicles are scheduled to be sent out the week of August 23.  WeÂ’ll note that Ford is reporting six “allegations of injury” related to this issue. For those who donÂ’t live in the high-corrosion states/their car was never registered in those states, Ford is offering a customer satisfaction program in case you were interested in having the work done anyway. 2020-21 Lincoln Aviator Lincoln is pulling back 40,995 new Aviators due to an improperly secured battery cable wire harness. This recall applies to gasoline-only versions of the Aviator, so Grand Touring PHEV buyers neednÂ’t worry. The wire harness may contact the AC compressor pulley due to it being secured improperly. Ford says that over time, the pulley could rub through the wire harnessÂ’ insulation, resulting in a short circuit and ultimately a fire. However, Ford is not currently aware of any injuries or fires related to this concern as of now. When you bring your car in, the dealer will inspect all the parts to determine what needs to be done. Fixes range from a basic tie strap to keep the harness away from the pulley (if it hasnÂ’t made contact yet), to replacement of the wire harness and AC belt if the contact has caused damage. Owners should expect to be notified the week of July 30 if their Aviator is involved in the recall.