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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

Autoblog Minute: VW Emissions Scandal, New Ford Super-Duty

We got our first looks at look at Ford's new Super Duty truck lineup this week but it's Volkswagen that has been dominating the news cycle, as Matthias Muller is named CEO of the embattled automaker. Autoblog's Senior editor Greg Migliore reports on the recap edition of Autoblog Minute. Show full video transcript text [00:00:00] We got our first looks at look at Ford's new Super Duty truck lineup this week but it's Volkswagen that has dominated the news cycle as Matthias Muller is named CEO of the embattled automaker. I'm Senior editor Greg Migliore and this is your Autoblog Minute Weekly Recap. Super Duty is new for 2017. Our first look at these heavy duty trucks showed increased cab space for passengers, and [00:00:30] a lighter aluminum frame. Ford insists these changes will provide customers with increased towing capacity and fuel efficiency. The all-new Super Duty will be built at Ford's Kentucky Truck Plant, and it goes on sale in late 2016. Now, in case you missed it Volkswagen is under fire for gaming EPA emissions testing. A massive government recall is in the works and the world's top-selling automaker is looking at significant losses in both car sales and its stock value. On top of losing billions of dollars, Volkswagen is also facing [00:01:00] legal issues. And this week we saw Martin Winterkorn step down as CEO of Volkswagen Group. These changes mark just the beginning of VW's arduous process of rebuilding consumer trust. Those are the highlights from the week that was. Be sure to check out my full recap this Saturday, plus some added insight on the Buick Cascada and its pricing strategy. For Autoblog, I'm Greg Migliore. Autoblog Minute is a short-form video news series reporting on all things automotive. Each segment offers a quick and clear picture of what's happening in the automotive industry from the perspective of Autoblog's expert editorial staff, auto executives, and industry professionals.

NHTSA investigating 250k F-150s for possible power brake failure

The National Highway Traffic Safety Administration is opening a preliminary evaluation into the 2011-2012 Ford F-150 with the 3.5-liter EcoBoost V6 because of potential failure of the power braking assist. If a recall is required, it could affect an estimated 250,000 of the trucks. This investigation is prompted by NHTSA receiving 32 complaints about the electric vacuum assist pump allegedly failing in these trucks, which then causes the power braking assist to stop working. Drivers claim having no warning beforehand. There are also two reports of crashes that are purportedly linked to the problem, but the government agency lists no injuries. According to NHTSA, the issue may be getting worse because 60 percent of these allegations are from the past nine months. A preliminary evaluation doesn't necessarily lead to a recall, though. NHTSA uses them "to assess the cause, scope and frequency of the alleged defect." Ford spokesperson Kelli Felker tells Autoblog: "We will cooperate with NHTSA on this investigation, as we always do." Related Video: INVESTIGATION Subject : Brake Vacuum Pump Failure Date Investigation Opened: JUN 22, 2015 Date Investigation Closed: Open NHTSA Action Number: PE15026 Component(s): SERVICE BRAKES, ELECTRIC , SERVICE BRAKES, HYDRAULIC All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD F-150 2011-2012 Details Manufacturer: Ford Motor Company SUMMARY: The Office of Defects Investigation (ODI) has identified 32 complaints alleging electric vacuum assist pump failures resulting in loss of brake power assist and increased brake pedal effort in model year (MY) 2011-2012 Ford F-150 full-size pickup trucks equipped with 3.5L GTDI engine. None of the complaints reported any warning indicators to alert the driver of brake power assist loss or the potential of increased stopping distance. Two reports alleged crashes due to increased brake pedal effort required to stop or slow the vehicle. The complaints show an apparent increasing trend, with approximately 60 percent of complaints received within the past nine months. A Preliminary Evaluation has been opened to assess the cause, scope and frequency of the alleged defect.