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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.

11 vehicles from Barrett-Jackson Las Vegas worth watching

This weekend will see the world's collector car crowds descend on Las Vegas, NV for one of the biggest shows on Barrett-Jackson's popular auction circuit. There are hundreds of vehicles up for bidding, ranging from a brand-new Lamborghini Aventador to a spattering of Art Deco classics and a huge swath of classic muscle cars.
While it's virtually impossible to assemble an inarguable list of the best cars coming during the three-day, 700-plus vehicle auction, we've sifted through the listings for this year's show - it was a tough assignment, we promise - and assembled a list of what we think will be some of the most interesting lots. We'll admit, it's a bit heavy on American iron, but if you browse BJ's listings, you'll come to a similar conclusion. Still, scroll down for our list of what we think will be the most interesting vehicles at the upcoming auction.

Ford issues recalls for Fiesta, Fusion, E-Series, and Lincoln MKZ

Ford has issued two new safety recalls for North America. The first covers certain 2014-15 Ford Fiestas, 2014-16 Ford Fusions, and 2014-16 Lincoln MKZs with doors that might not close properly. The second pertains to 2021 Ford E-Series stripped chassis and cutaway vehicles with a wiring harness that might chaffe and expose important wiring.    Ford is recalling 268,343 Fiesta hatchbacks, Fusion sedans, and MKZ sedans across the United States, Canada, and Mexico, with 248,912 of the affected vehicles located in the U.S. The recall says the "latch pawl spring-tab design" could crack in locations where the temperature gets too hot. If the tab breaks, the door might not shut. Or, worse, the door will shut temporarily and reopen once the vehicle is in motion. As a fix, Ford dealers will remove and replace the side door latches. In a separate recall, Ford is targeting 3,631 2021 E-Series stripped chassis and cutaway vehicles. These vehicles could have frame-mounted wiring harnesses that could deteriorate and break due to rubbing on the frame. If the chaffing wears down the harness, wiring for the fuel, trailer tow, and antilock braking systems could be exposed and damaged. In the worst-case scenario, the damage to the fuel pump wiring could cause the pump to stop working, which could stall the vehicle.  Those with affected E-Series vehicles should bring them in to dealerships for inspection. If there is no damage, technicians will add anti-abrasion tape over the area and "ensure clearance to surrounding components." If the harness is damaged, the wiring will be spliced and fixed, then anti-abrasion tape will be added. Ford also issued a third recall, but it is specifically for the Canadian market. On 54,292 examples of 2006-10 Ford Fusions, 2006-10 Mercury Milans, and 2006-10 Lincoln MKZs, a valve inside the hydraulic control unit might stick open. According to Ford, this could result in a longer brake pedal travel, which could possibly create dangerous situations if the driver is unaware. Dealerships will inspect the control units and replace those that are defective. Related Video: This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. 2021 Ford Bronco and Bronco Sport Leaks!!