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Ford adding second supplier for F-150 frames

Metalsa, the company that builds steel frames for the aluminum-bodied Ford F-150, is still having trouble providing enough frames to supply the two factories that build the pickup. The snafu is preventing Ford from selling as many of the country's best-selling truck as it could, and eating into profits - even though the bottom line is still breaking company records. According to The Wall Street Journal, Ford has picked Michigan company Tower International as a second frame supplier and expects to have inventory up to a proper level at the beginning of Q4 of this year. Neither Ford nor Tower would confirm the development - Automotive News got comments from a source and pieced together bits of info from Tower's financial statements and local press reports. Tower currently builds body structures for several vehicles, including the F-series, and the Bellevue, Ohio factory that will build F-150 frames previously manufactured frames for the Ranger and Econoline. According to a story in the local Sandusky Register, Tower will add one production line at the end of next month to begin shipping frames in October, and another line in April 2016. Something like 138 full-time workers and 364 robots are expected to carry out the work. Tower's most recent financial statement said that capital investment will be necessary to get everything set up, but the contract will be worth $140 million in yearly revenue.

Ford could make as much as $13k profit for every F-150

The Ford F-Series is a perennial member of the US bestseller list with the title in its brawny grasp for over 30 years, and the truck ranks as the top-selling model over $50,000 in the country. It shouldn't come as a shock then that the model is a major buttress of Ford's bottom line. Have you ever wondered just how vital the trucks are to the Blue Oval's health, though? Some math based on recent figures suggests they might be even more important than you think. Automotive News recently did the calculation and came up with that each F-150 sold contributed about $13,333 to the company's profits. That number was based on a statement from Ford CFO Bob Shanks that the automaker could have made another $1 billion in North America for the first quarter with a repeat of last year's sales of the F-150 and Edge, with 60,000 more trucks and 15,000 additional crossovers. If those 75,000 missing vehicles cost the company $1 billion, then they averaged $13,333 each. Also, the F-150 makes up 80 percent of the lost sales, so you might even conclude that each pickup brings even more money into Ford. Automotive News also extrapolates further. Based on a forecast of 800,000 F-Series sales this year, that's about $10.7 billion going into Ford's coffers. Obviously, these figures are far from exact since they are based on a single statement from the automaker's CFO. Autoblog reached out to Ford to see if the numbers were accurate, but the Blue Oval wouldn't comment on vehicle profitability. However, AutoPacific analyst Dave Sullivan suggests these figures could be on the right track, if a bit high. "The rough guess has been $10,000. Obviously that is a little different for a $60k truck vs a regular cab 4x2 work truck, but $10,000 is the ball park that is used," he said to Autoblog. If you ever wonder why Ford might be loathe to bring the smaller Ranger back to the US when it's available elsewhere, these huge profits are likely part of the answer. The Blue Oval has little reason to cut into the sales of a model that makes the brand billions. Related Video:

NHTSA closes Ford F-150 EcoBoost acceleration probe

Typically when we report on the findings of an investigation from the National Highway Traffic Safety Administration, it's because the government body has discovered a safety issue and prescribed a recall. In this case, however, NHTSA has closed an investigation into a reported performance deficit without ever getting to the recall stage.
The issue revolves around the Ford F-150 - specifically those equipped with the 3.5-liter EcoBoost engine - of which some 360,000 were built in the 2011, 2012 and 2013 model years. After receiving an initial 95 complaints, NHTSA opened an investigation last May - almost a year ago - into the reported issue of reduced engine power under hard acceleration. The agency has since received a total of 525 such complaints, and Ford itself reported receiving over 4,000.
Together, NHTSA and Ford determined that the problem resulted from cylinders misfiring, an issue itself stemming from water getting into the charge air cooler (CAC) mated to the turbochargers. In particularly humid or rainy conditions, water was found to get into the CAC, causing some of the cylinders to misfire, which in turn triggered the ECU to disable those cylinders in order to protect the catalytic converter from damage.