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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.

Watch how Ford torture-tested the 2015 F-150

The Ford F-150 has been the best-selling truck in the United States for the past 37 years, and the best-selling vehicle outright for the past 32. That's quite a legacy, and thus, it's no surprise that Ford worked super-duper-extra hard on creating the all-new, aluminum-bodied 2015 F-150 that debuted at the Detroit Auto Show earlier this year.
During an event at the company's headquarters in Dearborn, MI this week, we were able to see all of the ways that Ford endurance tests, not just the new F-150, but all of its vehicles. From examining things like light exposure to interior materials and paint finishes, to making sure that corrosion absolutely does not happen when steel components come in contact with aluminum panels in the new truck. The goal: ensure that the new F-150 is nothing short of "Built Ford Tough."
But that's only a small part of the story. Of course, the new F-150 has to be able to withstand whatever a pickup buyer might throw at it - and truck buyers arguably demand the most from their vehicles. So in an effort to convey just what the new F-150 had to go through before being given the final go-ahead, Ford has released a series of videos, showing how its new halo truck was indeed torture tested.

2014 Ford F-150 gets CNG option

Ford is toiling away, installing heavy-duty engine components into select 3.7-liter V6s to allow them to run on compressed natural gas (CNG) and liquid petroleum gas (LPG) in addition to gasoline. That's nothing new, but now, Ford has announced that it will offer the 2014 F-150 with this engine configuration, bringing the Blue Oval's total number of CNG/LPG-friendly vehicles up to eight. The F-150 will be the only half-ton pickup on the market that can run on these gases.
Ford will charge $315 per vehicle to equip the optional engine, but the trucks won't be ready to run on the alternative fuels straight from the factory and must be upfitted with additional equipment. A Ford Qualified Vehicle Modifier will install a separate fuel system for the compressed gases at a cost of $7,500 to $9,500, depending on fuel tank size. With the right-size tank, the F-150 equipped with the CNG/LPG-prepped engine can go 750 miles on one tank of gas, according to Ford, averaging 23 miles per gallon.
The practice of offering flex-fuel vehicles is gaining momentum as businesses take advantage of cheap gas. CNG can be bought for $2.11/gallon on average (per gasoline equivalent), and sometimes for as little as $1.00 in some parts of the US, Ford states. "With the money saved using CNG, customers could start to see payback on their investment in as little as 24 to 36 months," says Jon Coleman, Ford's fleet sustainability and technology manager. The automaker expects to sell a total of 15,000 CNG/LPG-prepped vehicles in the 2014 model year.