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NHTSA investigating Ford's solution to May 2014 power steering recall

The National Highway Traffic Safety Administration is investigating a complaint that Ford's response to a May 2014 recall of the 2008 to 2011 Ford Escape and Mercury Mariner doesn't quite go far enough to solve a troubling power-steering problem. Roughly a year ago, Ford recalled nearly a million vehicles after it was found that a problem with the torque sensor's communication with the power steering control module could cut steering assistance for drivers. While manual steering would still be available, the problem was enough to ask drivers to report in to have the PSCM inspected, and if necessary, replaced (along with the torque sensor, or in dramatic cases, the entire steering column). That would only happen, though, if trouble codes were being thrown. If there weren't any problems, dealers were told to simply update the PSCM's software so that any issues between it and the torque sensor would simply throw a visual and audio warning – power steering would still be maintained. The petitioner claimed that following the recall work, he still experienced a problem with the torque sensor. According to NHTSA, a claim was made that Ford didn't go far enough in its solution to the problem, and that "the software update itself may in fact cause further issues with the affected vehicle's power steering, causing it to fail, and ultimately requiring replacement of the torque sensor or entire steering column." The petition was filed in early February and is now officially being looked into by NHTSA.

Aluminum lightweighting does, in fact, save fuel

When the best-selling US truck sheds the equivalent weight of three football fullbacks by shifting to aluminum, folks start paying attention. Oak Ridge National Laboratory took a closer look at whether the reduced fuel consumption from a lighter aluminum body makes up for the fact that producing aluminum is far more energy intensive than steel. And the results of the study are pretty encouraging. In a nutshell, the energy needed to produce a vehicle's raw materials accounts for about 10 percent of a typical vehicle's carbon footprint during its total lifecycle, and that number is up from six percent because of advancements in fuel economy (fuel use is down to about 68 percent of total emissions from about 75 percent). Still, even with that higher material-extraction share, the fuel-efficiency gains from aluminum compared to steel will offset the additional vehicle-extraction energy in just 12,000 miles of driving, according to the study. That means that, from an environmental standpoint, aluminum vehicles are playing with the house's money after just one year on the road. Aluminum-sheet construction got topical real quickly earlier this year when Ford said the 2015 F-150 pickup truck would go to a 93-percent aluminum body construction. In addition to aluminum being less corrosive than steel, that change caused the F-150 to shed 700 pounds from its curb weight. And it looks like the Explorer and Expedition SUVs may go on an aluminum diet next. Take a look at SAE International's synopsis of the Oak Ridge Lab's study below. Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO2e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production ("Baseline"), an advanced high strength steel and aluminum design ("LWSV"), and an aluminum-intensive design (AIV).

GM, Ford, FCA and the UAW form joint coronavirus task force

General Motors, Ford and Fiat Chrysler are forming a coronavirus task force along with the United Auto Workers union to improve protections for their employees and limit the spread of the highly contagious virus. The task force, which would be focusing on areas including vehicle production plans, is being headed by UAW President Rory Gamble, GM Chief Executive Officer Mary Barra, Ford CEO Jim Hackett, Ford Executive Chairman Bill Ford and FCA CEO Michael Manley, the parties said in a joint statement on Sunday. Though automakers typically schedule plant staffing to allow for a certain proportion of absent workers, according to industry consultants, if the outbreak causes higher levels due to infection or workers staying home to care for children whose schools are closed, that could lead to reduced production or in extreme cases shutdowns. Production at an FCA assembly plant in Canada was halted for 24 hours after employees there refused to work on Thursday over fears of an employee being possibly exposed to the coronavirus. Separately on Thursday, the Italian-American automaker said that one of its employees had tested positive for COVID-19, a respiratory disease caused by the new coronavirus, at its transmission plant in Indiana. The plant, however, remained open. "This is a fluid and unprecedented situation, and the task force will move quickly to build on the wide-ranging preventive measures we have put in place," the CEOs of the three companies said in the statement. The task force would also be focusing on aspects such as health and safety education, health screening, food service at the automakers' locations. Related Video: Government/Legal Plants/Manufacturing UAW/Unions Chrysler Fiat Ford GM coronavirus