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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

Next Lincoln Navigator to drop V8 in favor of V6, but Ford Expedition might get both

A great many buyers fled from full-size body-on-frame SUVs to car-based crossovers in large measure to save fuel. But that doesn't mean there's still not a buying audience for more traditional truck-based utility vehicles, and those consumers doubtlessly wouldn't mind saving some dollars at the pump, too. According to Motor Trend, those shoppers might be in luck.
That's because the magazine has confirmed that Ford isn't walking away from the full-size SUV segment, and it's poised to do something about its offerings' economy ratings, too. According to MT, global Lincoln director Matt VanDyke has hinted that the next Navigator may drop two cylinders and go with a V6 model - the current model gets just 14 miles per gallon in the city and 20 on the highway from its 5.4-liter V8. The obvious fitment would be Ford's 3.5-liter twin-turbo EcoBoost V6, an engine that has spread like kudzu throughout the rest of the Blue Oval's large vehicle lineup.
Downsized turbocharged engines like Ford's EcoBoost franchise have come under fire as of late for not delivering their EPA fuel economy ratings, but their benefits extend beyond consumption - the 3.5L offers superior power and a better torque curve than the naturally aspirated V8. MT also suggests that Ford's 3.7-liter V6 could form the base engine for the next Navi - it has similar horsepower but a lot less torque than the current 5.4L. That may be less of a problem with the next generation tipped to go on a diet, which could level the playing field somewhat.

The 2021 F-150 elevates Ford's bed game

The new 2021 Ford F-150 is ushering in a new era of pickup capability, but there's more to it than the introduction of the PowerBoost hybrid. While that new powertrain is certainly the truck's headlining element, the supporting electrical architecture enables a level of utility that hasn't been offered in past consumer half-tons. The true party trick is Ford's new "Pro Power Onboard" feature, which is essentially a built-in generator that provides juice for the 2021 F-150's rather robust in-bed power station. This system is available even on gasoline-engine models, but its utility is maximized with the electrified powertrain. ICE models equipped with the option max out at 2.0 kilowatts, while the PowerBoost hybrid can be had with either a 2.4- or a whopping 7.2-kilowatt inverter.  The idea here is that the F-150 can essentially stand in for a high-output portable generator. In a worksite example provided by Ford, a PowerBoost model with the 7.2-kW upgrade and a single tank of fuel could provide 32 hours of power for an 1,800-watt compound miter saw, a 1,000W circular saw, a 1,200W battery charger, a 1,200W hammer drill, and a 1,000W air compressor with hundreds of watts to spare for lighting and other accessories. But even without the Pro Power Onboard option, Ford's new bed setup enables more versatility than in previous models. The new Tailgate Work Surface option adds a flat work area with integrated rulers, recesses for pencils or small tools, and even a stand for a personal device.  Ford is neither the first to offer an auxiliary power outlet in a half-ton pickup bed, nor was Ford the first to introduce a more feature-rich tailgate. GMC's MultiPro tailgate was a major innovation on that front, and while it is geared mostly toward improving the cargo utility of the bed, it can also be customized with 12-volt power and even an accessory speaker system. The Ram 1500 is also offered with both a multi-function tailgate and AC power in the bed, though the latter option is limited to models with the RamBox cargo package.  As half-ton pickups approach levels of towing and hauling capability that begin to blur lines with heavy-duty offerings, it's clear that automakers are looking for ways to differentiate themselves without stepping on their own bigger trucks' toes. These new bed and tailgate innovations may yet be the tip of the iceberg when it comes to full-size pickup versatility. Related Video: