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Ford adds 850 jobs to build 2015 F-150

Pickup trucks tend not to advance at quite the same pace as the rest of the industry. That's what makes the new Ford F-150 so remarkable, jettisoning its old steel construction in favor of aluminum. It's a game changer that Ford is betting big on, and in anticipation of surging demand, the Blue Oval automaker is adding 850 new jobs to put the thing together.
Those 850 new employees will be centered at Ford's Rouge complex in Michigan - with 300 at Dearborn Stamping, 50 more at Dearborn Diversified and 500 at the Dearborn Truck facility, the latter of which has already kicked off what Ford describes as "the largest manufacturing transformation in decades." Old manufacturing equipment is being replaced with the latest technologies, and even the Ford Rouge Factory Tour is undergoing a complete overhaul.
The new jobs come as part of the commitments Ford made to the UAW in 2011 to create 12,000 hourly jobs in the United States by 2015 - a number which Ford has already exceeded at 14,000. Over 4,000 of those are centered in southeastern Michigan.

2015 Ford Transit

As a segment, fullsize vans are stealth-fighter invisible on most consumers' radar. Visit a dealership for any of the four brands that offer them and you'll be lucky to find even one on display. These are commercial vehicles primarily, even more so than pickup trucks. Vans are the shuttles for plumbers, caterers, carpenters, concrete layers, masons, electricians, florists and flooring, and a huge part of this country's productivity is accomplished using them. At the moment, Ford is the 800-pound gorilla in that room - fully 41 percent of commercial vehicles wear a Blue Oval. So when Ford announced three years ago it would be ditching its commercial bread-and-butter E-Series, it meant the Transit that would be replacing the Econoline had huge, 53-year-old shoes to fill.
We were still a bit nostalgic about Econoline vans going away until going directly from the Transit first drive in Kansas City to an E-350 airport shuttle. Climb up through the Econoline's tiny double doors and bang your head on the opening, crouch all the way to your seat then enjoy a loud, rattle-prone, creaky, harsh ride on beam-hard seats while struggling to see out the low windows. This is an experience nearly every traveler has had. By comparison, the Transits we'd just spent two days with were every bit of the four decades better they needed to be. It cannot be understated just how much better the Transit is in every single way. The load floor is barely more than knee high. There's a huge side door, and hitting your head on a door opening is nearly impossible. Stand up all the way if you're under six-foot, six-inches - no more half-hunching down the aisle. There are windows actually designed to be looked out of. The ride is buttery smooth, no booming vibration from un-restrained metal panels and no squeaks. Conversations can be held at normal levels rather than yelling over the roar of an ancient V8. The seats are comfortable. The AC is cold. There are cupholders.
Enough anecdote-laying, what's in a Transit? We're talking about a very fullsized unibody van that's enjoyed a 49-year history in Ye Olde Europe. This latest iteration is part of the "One Ford" initiative, so it was designed as a global offering from the get-go, eschewing the body-on-frame construction the E-Series has used since 1975. Instead, the Transit integrates a rigid ladder frame into an overall frame construction made of high-strength cold-rolled and boron steel. The suspension is a simple but well-tuned Macpherson strut array up front with a rear solid axle and leaf springs.

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.