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Ford F-150 extended cab struggles in IIHS small overlap test

Update: Ford issued a statement to Autoblog to clarify the results of the test and dispute the IIHS repair cost estimates. A quote from a Ford representative has been added to the story. See the full statement below the IIHS press release. Of all the vehicles undergoing crash tests this year, few will be as closely watched as the new 2015 Ford F-150. That's not only because it remains the top-selling vehicle in America year after year, but also because it features an aluminum body instead of steel. While the F-150 performed well in the Insurance Institute for Highway Safety test, one factor prompted the institute to undertake a second round of testing that uncovered a problem. Like most full-size pickups, the F-150 is available in several cab styles: the regular two-door, the extended SuperCab and the four-door SuperCrew. The IIHS typically takes the most popular version of a particular model for testing, and in the Ford truck's case that meant the SuperCrew. The F-150 performed well in all the tests the IIHS put it through, including the small overlap test in which the vehicle is driven 40 miles per hour into a five-foot-tall barrier impacting the front left corner of the vehicle. Its overall performance in the tests earned the F-150 a Top Safety Pick rating, missing out on the higher Top Safety Pick + rating only because it doesn't have an automatic braking system. But how do the other versions of Ford's best-seller hold up? Given that even less popular versions of the F-150 still sell more than many other vehicles on the market, the IIHS put an extended cab through the same battery of tests. It performed comparably except in one area: the small overlap test. In that case, the extended cab model's steering column was pushed eight inches into the cabin (dangerously close to the crash test dummy's chest), the dummy's head missed the airbag almost entirely and hit the instrument panel, and the dummy's legs would risk sustaining "moderate" injuries. The reason for the disparity is that "Ford added structural elements to the crew cab's front frame to earn a good small overlap rating and a Top Safety Pick award but didn't do the same for the extended cab," according to the Institute's chief research officer David Zuby. "That shortchanges buyers who might pick the extended cab thinking it offers the same protection in this type of crash as the crew cab.

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.

Will Ford's SUV blitz include the Bronco?

Ford announced this week it will add four sport-utility vehicles in the next four years, an ambitious bet on a segment the industry once shunned. This led to wild speculation about what form these utes will take. Here's what we know: They will be new nameplates, and Ford is thinking globally. That means at least one might not be a product with US intent. They will also be in segments where the company does not currently compete, Ford said. The Blue Oval isn't specifying exactly what's it's doing, so here are some of our theories. We think one will be called the Bronco, which is great news for enthusiasts. We hope it follows the Mustang playbook with some heritage styling, but a thoroughly modern execution. Ford needs an off-road Jeep Wrangler-fighter. Fuel prices are low and it's been 22 years since the infamous O.J. Simpson white Bronco chase. This is the best chance Ford will ever have to bring back this iconic name. Our man on the ground at the Chicago Auto show, Sebastian Blanco, reported that Ford sales and marketing vice president Mark LaNeve said a "mini utility" will also be one of the utes. This could be primarily an overseas play. We've also seen lots of spy shots of the EcoSport, a small crossover that Ford sells in India and other overseas markets, being tested on American roads. That is an existing nameplate. Maybe Ford adds a small ute related to the EcoSport in the United States, but calls it something else. We think Lincoln gets a three-row SUV out of the deal. It could slot between the MKX, which was new last year, and the Navigator. Lincoln is leaving money on the table by not being in this segment. The platform could be used for a Ford at some point, too. The Blue Oval brand does actually have a tweener three-row vehicle, the Flex, but this chassis might underpin a replacement. Or maybe Ford makes one of these a hybrid. The company laid out ambitious plans in December to ramp up its electrification strategy, something that could mean a dedicated hybrid SUV (Kia unveiled one of those right after LaNeve's speech in Chicago). It's also possible hybrid technology will be integrated into this new portfolio. The Escape used to have a hybrid sibling. Whatever form they ultimately take, Ford is betting heavily on SUVs. The company thinks they are what Baby Boomers and Millenials want and expects the segment will continue to grow. It's important to note: this will be a diversified strategy.