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2020 Ford Explorer, Lincoln Aviator reportedly facing numerous QC issues

A lengthy report in the Detroit Free Press delves into a range of quality control issues confronting the 2020 Ford Explorer and its luxury platform sibling, the 2020 Lincoln Aviator. Freep says it's been following the issue for two months, tapping various unnamed sources for information on the automaker's unorthodox route to resolution. Seems the problem is Explorers and Aviators leaving the production line at the Chicago Assembly Plant with flaws in areas like the chassis, transmission and suspension, said vehicles trucked to Ford's Flat Rock Assembly Plant (FRAP) outside of Detroit for repair. The estimates range from 10,000 to 18,000 vehicles affected, numbers so high that Ford has sought help from Roush Engineering in nearby Allen Park, and brought workers and managers from other plants in the Midwest to FRAP to get vehicles repaired and shipped to dealers. Ford hasn't shared the nature of the problems with anyone outside the company, including dealers and customers. Freep's sources are said to include workers who have provided photos of certain vehicles and of tents used to house parts at the FRAP repair site. The Explorer chassis allegedly has an unidentified problem that engineers are using X-rays to diagnose, and the transmission is having problems sensing when it's in park or going into park. Both the Explorer and Aviator have come off the line with HVAC units that only blow hot air. And the Aviator's height-adjustable suspension enters failure mode for unknown reasons. These come on top of quotidian mishaps common to every new vehicle, but that are meant to be sorted in pre-production, like missing emblems and trim pieces. They also come on top of a recall in early August issued for the Explorer and Aviator concerning the instrument cluster and parking brake, and another at the end of August over rear seatbacks that could collapse in a crash. An automaker spokesperson told Freep, "Making updates to preproduction models based on all-new platforms as they roll off the assembly line – is standard industry practice." Except these aren't pre-production, these are early production vehicles that paying customers and dealers are waiting for, and some of the affected vehicles have been pulled off dealer lots. Dealers say they are fine waiting for the trucks to get sorted out, and they'd rather have Ford fix the problems before the SUVs go to customers.

NHTSA closes Ford F-Series Super Duty steering probe without recall

The National Highway Traffic Safety Administration's investigation into 2008 Ford F-250 and F-350 Super Duty pickups, which was originally opened last year, has now ended without a recall. NHTSA was looking into steering failures on some 336,000 trucks.
The issue rested with the steering gear - NHTSA received five complaints of failures - which was redesigned in 2005. According to the report on the matter, investigators "found evidence of broken sector shaft gear teeth and piston damage consistent with incidents of single event overload."
NHTSA investigators, however, "found no evidence of fatigue or material property defects in any of the fractures. Analysis of complaint rates by vehicle build month showed no patterns indicating potential manufacturing quality issues and no difference before and after Ford introduced design changes to the input shaft and sector shaft seals in July 2007 to address potential leak concerns," according to the report, obtained by The Detroit News.

Lincoln Nautilus, Ford Edge latest prediction: Production ends in July 2024

In June, Auto Forecast Solutions put out a report compiled by its vice president of global forecasting, Sam Fiorani. One item in the report covered how Fiorani had heard from "multiple sources" that Ford shut down the program to replace the Edge crossover in 2023. Assuming this came to pass, with the Lincoln Nautilus based on the Edge, the inference is that the Nautilus would retire at or around the same time. Ford's response to media queries about the report was either "No comment" or PR-speak deflection. Lincoln's statement on the matter to Motor1, a crafty non-answer, was, "The Nautilus plays and will continue to play an important role in Lincoln’s growing SUV portfolio which includes the Corsair, Aviator and Navigator. Lincoln is investing in growth segments like SUVs and we have no plans to exit the segment." It's possible Lincoln has no plans to leave the segment, but the Nautilus might, according to a fresh, unsourced report in Ford Authority. The site claims the Nautilus will end production at the Oakville Assembly Plant in Ontario, Canada, in July 2024.  Again, we can't know how much, if any of this, is true. But we're zeroing in on a timeline for the potential end of the Edge and Nautilus in the U.S. Those are the only two products Oakville currently builds, and when the Canadian union Unifor asked Ford about the reports in June, Ford couldn't offer union reps anything concrete or reassuring. The Detroit News quoted Unifor chief Jerry Dias as saying of the automaker, "There is no question, they are going through a major evaluation of their portfolio, based on a whole host of things."   We could be seeing one of the earlier theories for Edge's potential demise coming true. Some analysts suspect Ford could be pruning its crossover lineup because it has too many similarly-sized offerings at the moment, the Edge hasn't met its sales targets in Europe, and more compact crossovers are on the way that could bring better street cred if they're associated with the Bronco or Bronco Sport. Unifor and Ford are now in negotiations over a new contract, so it's possible we'll get more clarity in the next month or so about Ford's plans and what will come of Oakville and its roughly 4,000 workers. If Ford walks away from the assembly plant, it will only have two engine plants left in Canada, and no vehicle assembly north of the border for the first time in about a century.