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Ford made three big mistakes in calculating MPG for 2013 C-Max Hybrid

It's been a rough time for the official fuel economy figures for the Ford C-Max Hybrid. When the car was released in 2012, Ford made a huge deal about how it would beat the Toyota Prius V, which was rated at 42 combined miles per gallon, 44 city and 40 highway. The Ford? 47 mpg across the board. How did Ford come to this place, where its Prius-beater turned into an also-ran? Well, after hearing customer complaints and issuing a software update in mid-2013, then discovering a real problem with the numbers last fall and then making a big announcement last week that the fuel economy ratings of six different 2013 and 2014 model year vehicles would need to be lowered, the C-Max Hybrid has ended up at 40 combined, 42 city and 37 highway. In other words, the Prius trumps it, as daily drivers of those two vehicles have known for a long time. The changes will not only affect the window sticker, but also the effect that the C-Max Hybrid (and the five other Ford vehicles that had their fuel economy figures lowered last week) have on Ford's compliance with greenhouse gas and CAFE rules for model year 2013 and 2014. How did Ford come to this place, where its Prius-beater turned into an also-ran? There are two technical answers to that question, which we've got below, as well as some context for how Ford's mistakes will play out in the bigger world of green vehicles. Let's start with Ford's second error, which is easy to do since we documented it in detail last year (the first, needing to do a software update, was also covered). The basic gist is that Ford used the general label rule (completely legally) to test the Fusion Hybrid and use those numbers to figure out how efficient the C-Max Hybrid is. That turned out to be a mistake, since the two vehicles are different enough that their numbers were not comparable, despite having the same engine, transmission and test weight, as the rules require. You can read more details here. Ford's Said Deep admitted that the TRLHP issue is completely separate from the general label error from last year. Now let's move on to last week's announcement. What's interesting is that the new recalculation of the MPG numbers – downward, of course – was caused by a completely separate issue, something called the Total Road Load Horsepower (TRLHP). Ford's Said Deep admitted to AutoblogGreen that the TRLHP issue had nothing to do with the general label error from last year.

70% of pickups could use aluminum by 2025

In the next decade, the auto industry will see an explosion in its use of aluminum to cut weight and increase fuel economy, according to a study from market analysts Ducker Worldwide cited by The Detroit News. We are already seeing the lightweight metal show up extensively in luxury models from Europe, but with the impending launch of aluminum-intensive 2015 Ford F-150 (pictured above), North America is using it even more, as well. The report predicts 70 percent of US pickups to have aluminum bodies by 2025.
It won't just be pickups that see the benefit, though. The average amount of aluminum in US vehicles is forecasted by the study to grow from an average of 350 pounds in 2013 to about 550 pounds by 2025. The most common parts to use it will be hoods, doors and - to some extent - roofs, as well.
The massive increase in pickups' aluminum content hardly seems surprising. The F-150 is predicted to use so much that it might cause a short-term shortage, according to one earlier report. At the same time General Motors is heavily rumored to be negotiating with suppliers for the next generation Chevrolet Silverado and GMC Sierra. Ram is the last holdout of the Big Three, but the study predicts that not to last.

New Ford dedicated hybrid due in 2018, will it fare better than C-Max?

Everyone likes to go after the champ. When it comes to fuel economy, that means taking on the Prius, which is something that automakers not named Toyota have been trying to do for years. Just because no one has been able to beat the Prius for fuel economy numbers isn't stopping them from trying. Hyundai was just caught with a potential Prius-fighter and now we have news that Ford is joining the party. Well, is going to join again. The last time Ford said it was going to challenge the Prius, it didn't go quite as planned. The C-Max hybrid was heavily hyped as a Prius-beater and was originally rated at 47 miles per gallon. Of course, it later needed to be recalculated to just 40 mpg and sales tanked. So, it's back to the Blue Oval drawing board, according to Automotive News, which is reporting that Ford is readying a brand new gas-electric hybrid due in 2018 as a 2019 model year vehicle. A plug-in version is in the works, too, and the car will reportedly share a platform with the upcoming next-gen Focus and Escape models. About those C-Max sales. They have not been stellar for the C-Max hybrid, which started strong but suffered when the reality of the lower fuel economy was realized. So far in 2014 (through the end of July), Ford has sold 11,685 gas-electric models and another 4,759 plug-in Energi versions. The trend for the standard C-Max is downward (from 20,125 during the same time frame in 2013) and upward for the plug-in version (2,915 in the first seven months of 2013).