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Ford expands 'Do Not Drive' airbag warning to 33,000 more Ranger trucks

WASHINGTON — Ford on Monday warned an additional 33,000 owners of older pickup trucks in North America to stop driving them until potentially defective Takata Corp airbag inflators can be repaired. In January, Ford told 2,900 owners of model year 2006 Ford Ranger trucks to stop driving immediately after a second death was linked to inflators built on the same day. The expanded warning was prompted by additional testing, Ford, the second largest U.S. automaker, said in a statement, and now covers a broader time frame of production. Mazda Motor Corp said it was issuing a similar expansion for about 1,800 2006 Mazda B-Series trucks that were built by Ford after it had issued a warning for 160 trucks in January. The National Highway Traffic Safety Administration (NHTSA) said the vehicles pose "an immediate risk to safety" and urged owners to immediately schedule a free repair. Ford and Mazda have replacement airbag inflators available now and will tow vehicles to a dealership for repairs as well as provide loaner vehicles free of charge, the companies and NHTSA said. About 90 percent of the vehicles subject to the "Do Not Drive" warning are in the United States. Two U.S. senators in January questioned why Ford's warning only applied to a small number of the 391,000 2004-2006 Ranger trucks recalled because of Takata air bags in 2016 in the United States. Ford said last month the death in a July 2017 crash in West Virginia in a 2006 Ford Ranger was caused by a defective Takata inflator after a similar 2015 death in South Carolina. At least 22 deaths worldwide are linked to the Takata inflators that can rupture and send deadly metal fragments into the driver's body. The faulty inflators have led to the largest automotive recall in history. The other 20 deaths have occurred in Honda vehicles, most of which were in the United States. About a quarter of the 2,900 vehicles have been repaired since Ford issued the warning last month, the company said on Monday. Takata said in June it has recalled, or expected to recall, about 125 million vehicles worldwide by 2019, including more than 60 million in the United States. About 19 automakers worldwide are affected. Takata inflators can explode with excessive force, unleashing metal shrapnel inside cars and trucks and have injured more than 200 people. The defect led Takata to file for bankruptcy protection in June.Reporting by David ShepardsonRelated Video:

Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

The redesigned 2019 Mazda3 moves way upscale

Mazda didn't lie — the 2019 Mazda3 is a gently reworked production version of the Kai concept shown at last year's Tokyo Auto Show. In hatchback and sedan forms, you'll still quickly peg this a Mazda3. The dimensions barely change: The wheelbase grows by an inch, but the hatchback width and length carry over, while height decreases by an inch; the sedan is the same width but 3.2 inches longer and 0.7 inches lower. Nevertheless, the look and details have evolved throughout, yielding a much more potent and piercing hatchback, and a more sophisticated, accomplished sedan. Instead of using hard shoulder and swage lines to "draw" contour onto a flat profile, Mazda designed a car with contours that create real shoulders and hips. Shedding the illusion of surface depth for reality redefines the look and presence of the Mazda3. The new model erases the hash of lines and embossed panels in back of the current car so that the S-curved hatch has only its shutline for framing. After that, the highlights enhance the theme. On either side of the larger grille, single-lens headlamps get new accents; instead of a just plain silver bar, streaks of amber turn signals decorate the more dimensional units. The contoured taillamp housing holds highly structured, highly embellished twin circles that probably look even more sinister at night. On the sedan, those naughty taillights are surrounded by a refined rear valance with a more angled, muscular lip along the trailing edge. It's the same inside, a design based on results of Mazda's in-depth studies of human mechanics. The flatter instrument panel stresses clean lines along the horizontal. Trimmer steering wheel spokes with silver buttons line up with the central span across the dash housing the climate control buttons and vents. The new shift panel sits higher and more forward, making it easier for the driver to move a hand from the steering wheel to the lever. To raise perceived luxury, the center tunnel trim is a clear layer laid over a laser-engraved black layer, said to produce a "look of deep transparency," and similar to the effect found on the new BMW X5 and X7. The cupholders are now in front of the shifters, and the armrest is longer. There's no mention of that digital gauge cluster that leaked earlier this year, though. Buyers who opt for fabric will get a new "Greige" hue, a mix of gray and beige. Mazda designed a new leather grain with creases of varying depths and shapes depending on where it's placed.