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Ford made three big mistakes in calculating MPG for 2013 C-Max Hybrid

It's been a rough time for the official fuel economy figures for the Ford C-Max Hybrid. When the car was released in 2012, Ford made a huge deal about how it would beat the Toyota Prius V, which was rated at 42 combined miles per gallon, 44 city and 40 highway. The Ford? 47 mpg across the board. How did Ford come to this place, where its Prius-beater turned into an also-ran? Well, after hearing customer complaints and issuing a software update in mid-2013, then discovering a real problem with the numbers last fall and then making a big announcement last week that the fuel economy ratings of six different 2013 and 2014 model year vehicles would need to be lowered, the C-Max Hybrid has ended up at 40 combined, 42 city and 37 highway. In other words, the Prius trumps it, as daily drivers of those two vehicles have known for a long time. The changes will not only affect the window sticker, but also the effect that the C-Max Hybrid (and the five other Ford vehicles that had their fuel economy figures lowered last week) have on Ford's compliance with greenhouse gas and CAFE rules for model year 2013 and 2014. How did Ford come to this place, where its Prius-beater turned into an also-ran? There are two technical answers to that question, which we've got below, as well as some context for how Ford's mistakes will play out in the bigger world of green vehicles. Let's start with Ford's second error, which is easy to do since we documented it in detail last year (the first, needing to do a software update, was also covered). The basic gist is that Ford used the general label rule (completely legally) to test the Fusion Hybrid and use those numbers to figure out how efficient the C-Max Hybrid is. That turned out to be a mistake, since the two vehicles are different enough that their numbers were not comparable, despite having the same engine, transmission and test weight, as the rules require. You can read more details here. Ford's Said Deep admitted that the TRLHP issue is completely separate from the general label error from last year. Now let's move on to last week's announcement. What's interesting is that the new recalculation of the MPG numbers – downward, of course – was caused by a completely separate issue, something called the Total Road Load Horsepower (TRLHP). Ford's Said Deep admitted to AutoblogGreen that the TRLHP issue had nothing to do with the general label error from last year.

Lincoln MKC recalled because start button located too close to touchscreen [UPDATE]

UPDATE: Ford spokesperson Kelli Felker responded to our questions and let us know that the fix for the push-button start on the 2015 MKC has the switch moved to the top of the of the column of gear shift buttons instead of the bottom. Owners should be notified about both campaigns "toward the end of February." After massive campaigns from General Motors and to fix Takata airbag inflators, 2014 will undoubtedly go down as The Year Of The Recall. And with little time to spare, Ford is getting in just under the wire to adding two more to its yearly total. The larger of the campaigns is actually one of the most bizarre campaigns we've heard of all year. Lincoln is recalling 13,574 units of its 2015 MKC compact crossover in North America to move the location of the push-button ignition switch on the dashboard. According to the automaker's announcement: "Due to the switch's close proximity to other controls, occupants are inadvertently shutting off the engine while driving." The button is located near the bottom of the touchscreen, which can apparently make it possible to hit by mistake. Back when Autoblog first drove the new MKC in June, we came away very impressed, but noted: "... we're still not completely sold on the aforementioned pushbutton transmission selector ... it still seems somewhat gimmicky and it can't be operated by feel alone, as you might when shifting a traditional console-mounted lever from Park to Drive." According to Lincoln, there have been no reported accidents or injuries stemming from this button misapplication. Of the affected vehicles, there are 11,144 in the US, 2,033 in Canada and 397 in Mexico. To fix the problem, dealers are moving the button to a different location and reprogramming the powertrain control module. According to Automotive News, models built since September already have a different layout. The change was reportedly done to match the rest of the Lincoln lineup. The second recall covers 12,205 units of the 2014 Ford Escape (2015 model year pictured below) and 2015 Lincoln MKC in North America because of a problem with nickel plating on the fuel pump. The issue can cause the pump to seize, which can cause the crossovers not to start or stall while driving. The automaker is not aware of any accidents or injuries related to this fault. Dealers are replacing the fuel deliver module to fix the situation. Of the affected vehicles, there are 9,038 in the US, 3,074 in Canada and 93 in Mexico.

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."