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2015 Ford F-150 enters production

Ford has given the F-150 a dramatic makeover for 2015, switching to an aluminum body that helps reduce weight by about 700 pounds. Because the truck is dramatically different, Ford also had to change the way it makes the F-150, so we went inside its sprawling factory in Dearborn, MI, this week to see the Blue Oval's new manufacturing techniques in action.
The company has added 850 jobs at the site and upgraded its stamping and tool and die facilities. The body shop is also modernized, and it has been fitted with 500 new robots that join the structures together. The first 2015 F-150 rolled off the line on Tuesday, and the trucks will begin arriving in dealerships in December. Get a closer look at the F-150's unique assembly process in our video.

2015 Ford Expedition stays the course, adds EcoBoost power

The era of the body-on-frame, fullsize SUV is rapidly vanishing in favor of smaller, unibody crossovers. However, Ford still sees life in the segment with the reveal of the updated 2015 Expedition, now available (solely) with the company's 3.5-liter EcoBoost V6. The new truck will make its public debut at the 2014 DFW Auto Show in Dallas on February 19.
The loss of the previous 5.4-liter V8 in favor of Ford's 3.5-liter, direct-injected, twin-turbocharged V6 engine might rankle some of the Expedition's fans, but Ford claims that the change gives the SUV better fuel economy, more power and increased low-end torque than before. Unfortunately, official engine specifications won't be released until later this year, but Ford says engine output will be similar to the 365 horsepower and 360 pound-feet of torque that this powerplant produces in other applications. The EcoBoost is mated to a six-speed automatic transmission, and the SUV now uses electrically assisted power steering, for an even greater fuel economy advantage. Ford claims this also allows for better maneuverability at low speeds and better feel at high speeds.
Exterior styling is basically unchanged for 2015. The front end has the same three-bar chrome grille and headlight design, but the lower air dam gets added chrome and LED lamps. The rear gets more brightwork on the hatch, and there's a chrome-tipped exhaust pipe. As before, Ford is offering the Expedition in two wheelbase lengths - 119 inches and 131 inches. A new, optional, continuously controlled damping system alters suspension settings constantly based on 46 parameters and offers comfort, normal and sport modes (just like the Expedition's sister, the recently refreshed and decidedly less-attractive Lincoln Navigator).

Ford will add lots of carbon fiber to new vehicles

With BMW receiving a bunch of positive press for its usage of carbon fiber to build its i3 and i8 plug-in vehicles, Ford is jumping into that game as well. The US automaker has reached a manufacturing agreement with Dow Chemical to speed up the use of that material in Blue Oval vehicles. Carbon fiber usage will cut weight from Ford's new products, boosting fuel efficiency as a result. Ford will work with DowAksa, a 50/50 joint venture between Dow Chemical and Turkey-based Aksa Akrilik Kimya Sanayii A.S, on a manufacturing partnership. The goal is to speed up technology research to make it cheaper to make cars and trucks with carbon fiber materials. Ford's light-weighting efforts received a boost of sorts this week when its aluminum-body 2015 F-150 was awarded a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing, making this year's version the safest to date. The new body construction cut 700 pounds from the truck's curb weight. Take a look at Ford's press release about DowAksa below. FORD, DOWAKSA TO JOINTLY DEVELOP CARBON FIBER FOR HIGH-VOLUME AUTOMOTIVE LIGHT-WEIGHTING APPLICATIONS Ford and DowAksa formalize agreement to advance the adoption of cost-effective carbon fiber components through technology validation and proof of concept to reduce vehicle weight and increase fuel efficiency without sacrificing strength Agreement provides pathway for a high-volume manufacturing partnership New joint development agreement accelerates joint research announced in January in partnership under new U.S. composites manufacturing institute Ford and DowAksa today signed a joint development agreement (JDA) to formally advance research on cost-effective, high-volume manufacturing of automotive-grade carbon fiber, a material poised to play a significant role in the drive to make vehicles lighter for greater fuel efficiency, performance and capability. The agreement, between Ford Motor Company, Ford Global Technologies and DowAksa – a 50/50 joint venture between The Dow Chemical Company and Aksa Akrilik Kimya Sanayii A.S – will combine DowAksa's feedstock capacity, carbon fiber conversion and downstream intermediates production capabilities with Ford's expertise in design, engineering and high-volume manufacturing. The goal is to produce materials that make cost-effective carbon fiber composite parts that are much lighter than steel but meet automotive strength requirements.