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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.

Ford updates Transit lineup for 2016

We have a strange affection for vans here at Autoblog, perhaps due to all that free candy we ate as kids. So when Ford announces some minor updates to the Transit and Transit Connect, we deliver the news that every plumber, electrician, and airport shuttle driver across the nation (and Canada) needs. The biggest item for 2016 is an optional passenger side sliding door on medium- and high-roof models, improving access to the Transit's cavernous interior. Ford's rollout of the much-improved Sync 3 infotainment system also expands to the to large van. And a reverse backup camera is now standard across the lineup. The little Ford Transit Connect is also tweaked for the next model year, right after we spent some time in the 2015 version. Titanium trim on the long-wheelbase wagon model brings second row bucket seats that fold flat. With XLT trim, you can swap out a bench seat for the buckets at no extra charge. Read on the for the full press release. FORD TRANSIT, TRANSIT CONNECT AND TRANSIT CONNECT WAGON EVEN SMARTER, MORE FLEXIBLE FOR 2016 MODEL YEAR SYNC® 3, Ford's new communications and entertainment system, is available for 2016 Ford Transit – making America's best-selling van even smarter Ford Transit built more than 100,000 vehicles in the 2015 model year Ford Transit Connect compact commercial van equipped with 2.5-liter I-4 engine gains flex-fuel capability for 2016 DEARBORN, Mich., June 4, 2015 – America's best-selling van is even better for the 2016 model year, with the addition of available SYNC 3, rearview camera technology and new customization options. "These and other updates make the 2016 Ford Transit the smartest, most flexible van ever offered by Ford," says Yaro Hetman, Ford brand manager for Transit, Transit Connect and E-Series. "Transit replaces America's best-selling van for 35 years, E-Series, first sold in 1961 as Ford Econoline, and we look forward to continuing our leadership in this important segment." Transit quickly took over the best-selling commercial van title in November 2014, having been available beginning in June at U.S. and Canadian dealerships for the first time. Ford has produced more than 100,000 Transit vans and wagons at Kansas City Assembly Plant during the 2015 model year.

A cool boost to turbocharger performance

Since the advent of the forced-induction engine, we have been looking for ways to get every drop of performance we can. There are many approaches to getting additional power using better intercooling, water injection, or even adding nitrous oxide. One take on a short instant burst of power is being researched by Mahle and involves providing supercooled air to an engine, which allows it to burn a leaner fuel mixture and produce more power. The supercooling idea is not new and was examined by Ford in 1993 on the Mustang Mach III concept car, then brought up again in 2003 with the SVT F-150 Lightning concept. Ford called its system the SuperCooler; it was designed to work with any turbocharged or supercharged engine equipped with a water-to-air intercooler. The system on the Lightning concept used a small tank of antifreeze that was hooked up to the truck air conditioning compressor. The air conditioning compressor cooled the antifreeze down to about 30 degrees. The other side of the tank was hooked up to the air-to-water intercooler, which usually had a temperature over 100 degrees. Once the antifreeze was circulated from the tank into the intercooler, it would lower the intercooler temperature and provide for a cooler, denser air charge into the engine; the result was around 50 extra horsepower for a burst of about 30 seconds to a minute, depending on the size of the tank. The system for the Lightning was to be offered as a $750 option and would have been targeted towards drag racers and the like, as it could be used for a run down the drag strip and then re-cooled by the time the truck was back in line. The system was fairly non-intrusive – it only weighed about 25 pounds and did not require a new compressor or intercooler. But as with many concepts, it was ultimately scrapped. The technology was always stuck in the back of my mind, but with larger and more powerful engines being produced it could not find its place. With the advent of new fuel economy standards, we have seen small-displacement turbocharged engines pop up and they seem like the perfect candidate for this type of technology. Ford's EcoBoost 1.0-liter three-cylinder turbocharged engine, as used in the Fiesta and Focus, is one such candidate for this technology. It would add a negligent amount of weight but could provide a boost of 10 to 20 horsepower when needed, like merging onto the highway or catching up to traffic.