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Recharge Wrap-up: Tesla details factory expansion; Ford and SunPower raise money for Sierra Club

Tesla has revealed the details of the upgrade of its Fremont, CA factory. One major change is the addition of a dedicated production space for the dual-motor P85D version of the Model S. Robots will be doing the battery installation on the Model S to save some time, and new export docks allow Tesla to get the cars out the door and on the way to their new owners more quickly. The new robots that move the cars around the factory have been named after X-Men characters, which makes our inner geeks smile. Check out the factory upgrade in the time-lapse video below and read more at Teslarati or at the Tesla Motors Blog. A program in Beijing for privileged registrations for EVs hasn't had much success. Of the 1,424 lottery winners, only about 30 percent went on to register an electric car despite a two-month extension of the deadline to do so. Buyers are likely discouraged by the lack of charging infrastructure, which the city hopes to ameliorate with the addition of 1,000 new charging stations by the end of the year, and by requiring new and renovated developments to set aside parking specifically for EV charging. Read more at Green Car Reports. The UC Davis Institute of Transportation Studies suggests that laws designed to protect dealers and consumers are stymieing the adoption of EVs. Laws like the ones certain states have in place that block or otherwise restrict Tesla's direct-to-consumer business model are not helpful for companies that want to introduce new products to the market. They prevent companies from passing on savings to customers for whom they would likely make the difference in a purchasing decision. One possible solution would be to allow exemptions to certain selling restrictions for a certain number of vehicles sold. "This could give automakers the degree of control needed to work out kinks with early customers, develop scalable processes for supporting PEVs, and ensure that effective dealer performance standards are in place before handing the reins over to wholly independent retailers," according to UC Davis ITS. Read more at the UC Davis website. Volkswagen says its environmental program, called "Think Blue. Factory," is meeting the automaker's own sustainability targets. The main purpose of the program is to move toward eco-friendlier carmaking at each of its plants worldwide.

2017-19 Ford Super Duty trucks recalled for tailgates that could open

Ford announced two separate recalls today, though neither has resulted in any known injuries. The first recall, which deals with a tailgate malfunction, affects 261,617 examples of 2017-2019 F-250, F-350, and F-450 Super Duty pickups. The second, which anticipates the possibility of a fuel leak, affects 3,893 units of 2020 Explorer and 2020 Lincoln Aviator SUVs with 3.0-liter engines. Ford says tailgates might accidentally open on some 2017-2019 Super Duty trucks because of a short circuit. If the pickups have an electric tailgate latch-release switch on the tailgate handle, water might get into the wiring. If the water hits the right spots, a short circuit could cause the switch to release the tailgate latch. In a worst-case scenario where the tailgate opens while driving, contents of the truck's bed could fall out and create a safety hazard. Dealerships will fix the problem by modifying the tailgate frame wiring harnesses with jumper pigtails and install a new tailgate handle release switch. Of the lot, 231,664 trucks are in the U.S., and 29,953 are in Canada. The Ford recall number is 19S48.  The second recall is much smaller, involving fewer than 4,000 vehicles. In certain 2020 Explorers and Aviators with 3.0-liter engines, Ford says, "The convolute protective sleeve on the liquid fuel line is not long enough, which may allow for potential hard contact with the convolute-protected vapor fuel line. Over time, with vibration and engine roll, hard contact between the two fuel lines could cause the convolute on the vapor fuel line to rub through the plastic liquid fuel line." If that happens, it could be a fire risk and hazardous for drivers and passengers. Only 35 of those SUVs are in Canada, and the rest are in the United States. Dealers will fix the problem by replacing the defective convolute with a full-length piece and tying it down with a strap. The recall reference number for the Aviators and Explorers is 19S49. The recall adds to what has otherwise been a rocky early production phase for the new Explorers and Aviators.

Aluminum Ford F-150 earns five-star crash rating [w/video]

The scores are in, and the 2015 Ford F-150 has been awarded a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing. That makes it, according to Ford, the safest F-150 ever. "The five-star safety rating is a terrific example of One Ford collaboration and innovation," Vice President of Global Product Development Raj Nair said in a statement. "Our truck team worked together for years to deliver this accomplishment, using an unprecedented combination of advanced materials throughout the all-new F-150. The 2015 model is engineered to be the safest F-150 ever, which matters to customers who depend on this truck to not only get the job done, but also get them safely home." The new F-150's aluminum and high-strength-steel construction posed some unique challenges to truck's engineers. "The team had to invent new ways to manage crash energy, because advanced materials like high-strength steel behave differently," Matt Niesluchowski, the truck's safety manager. "We found that changing certain shapes led to a weight reduction, while also improving crash performance." Beyond the structural safety features, the 2015 F-150 is loaded with additional safety features, including an adaptive steering column and Ford's inflatable seat belts, that protects drivers in the event of a collision. Beyond that, there's the usual array of active safety features meant to prevent a crash in the first place, including Curve Control and forward collision warning with brake support. Check out Ford's full press release on its five-star score, as well as video on the truck's safety features.