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Hot-selling Ford Expedition, Lincoln Navigator get production boost

Ford is investing an additional $25 million in its Kentucky Truck Plant in Louisville to increase by 25 percent production of the hot-selling and all-new Lincoln Navigator and Ford Expedition SUVs. The investment adds to $900 million in previously announced spending at the plant, which also builds F-Series Super-Duty pickups and employs 8,400 workers. Assembly-line workers are putting in overtime and working voluntary weekend shifts to keep up with demand. The new investment will cover upgrades to the assembly line but does not involve further hiring, Ford spokeswoman Kelli Felker says. The popularity of the Ford Expedition and Lincoln Navigator is a bright spot as Ford stock has been battered by Wall Street amid concerns concerns about the automaker's future vision and slowness to detect trends. Ford says the investment is an example of its bid to improve "operational fitness," one of CEO Jim Hackett's common refrains. Ford says Navigator retail sales more than doubled in January, and Navigators are spending an average of just seven days on Lincoln dealership lots as customers trade in vehicles including Land Rovers and Mercedes-Benz. Nearly 85 percent of buyers are opting for high-end Black Label and Reserve trim packages, contributing to an average transaction price increase of more than $21,000 in January compared to a year ago. The 2018 Navigator won the North American Truck of the Year award and also topped a Detroit News poll of public favorites at last month's Detroit Auto Show. Sales of the Expedition, meanwhile, were up almost 57 percent last month as the full-size SUVs also spent an average of just a week on dealer lots. Platinum trim models represented 29 percent of sales, pushing transaction price increases up $7,800. Ford gave the 2018 Expedition an all-aluminum body to save mass in its first significant redesign since 2007. The plant last year got nearly 400 new robots, mainly in the body shop, to help increase line speed, and Ford added a robot lab where employees can test software tweaks or troubleshoot issues away from the factory floor. The Louisville plant also benefits from extensive new data analytics, with seven big-screen monitors providing minute-by-minute updates showing progress against hourly targets or alerting workers to pending parts shortages. A huge spare-parts "vending machine" lets workers more quickly locate needed parts and keep inventory at necessary levels.

Want a new 2022 Lincoln Navigator? You'll have to custom order it

Lincoln showed the refreshed 2022 Navigator in August of last year, but the luxury SUV only entered production on January 18 of this year. After just three months of rolling down the line at Ford's Kentucky Truck Plant, Lincoln has closed the doors on pumping out inventory units. Ford Authority noticed the Navigator page at Lincoln's consumer web site now reads, "The 2022 Lincoln Navigator is only available for custom order. Some models, trims, and features may not be available. Please contact your local Lincoln Retailer for updates and assistance." It's a small bit of sub-optimal news for shoppers who want to hit the dealer lot and shop for an SUV like choosing a pet at a shelter. It hasn't been such a bad thing for Lincoln, though. Ford has made it intentions clear about the future of dealer inventory and custom orders, emphasizing that it wants less of the former and more of the latter. With the Navigator, that part of the plan appears to be working out, FA reporting that retail orders in February were up 291% over February 2021. Threads on the Blue Oval Forums show buyers willing to wait for their orders as well, one buyer who placed an order on January 20 still holding out for a VIN and tentative production date at the time of writing. It doesn't appear the move to custom orders is the result of overwhelming demand, however. Rather, it seems that Ford just can't make enough Navigators to satisfy what demand there is. Production issues at the Kentucky Truck Plant that also builds the Ford Expedition and Super Duty pickup have crimped output for all three models. Expedition and Navigator sales in the U.S. are both down more than 56% through the first three months of this year. Navigators that do make it out the plant doors are leaving without Active Park Assist 2.0, a standard feature on the Lincoln that is constrained on a number of Ford vehicles as well thanks to you know what. Ford is at least able to do the next best thing, which is installing an Active Park Assist 2.0 Prep Kit that screws in the sensors and hardware. When chips are available, which the automaker believes could be 12 to 18 months, an owner can stop by a dealer to have that chip installed free of charge. It's a nicer solution than a Semiconductor Shortage Package for everyone involved. Order books for the 2023 Lincoln Navigator are expected to open in two months, with production slated to start in September. Maybe things will be better then. Or not.

Slew of Ford recalls affect more than a million vehicles

Ford is closing out September with the sad task of alerting owners to five different recalls, two of them camera related. The first is a safety compliance recall affecting 620,246 units of 12 models from the 2020 model year: Edge, Escape, Expedition, Explorer, F-150 and Super Duty, Mustang, Ranger, and Transit, plus the Lincoln Corsair, MKX, and Nautilus. On these vehicles, the circuit board in the rearview camera suffers from insufficient electrical conductivity. The issue can cause the resulting image to not appear or to be distorted, which can lead to an accident while reversing. Ford will begin notifying owners as of November 7 to get their vehicles to dealers for replacement of the rearview camera. The internal Ford reference for this recall is 20C19. The second camera-related issue affects the 2020 and 2021 Ford Explorer, Lincoln Corsair and Lincoln Aviator with the 360-degree camera. Technically, if you own a 2021 Explorer that only has a rearview camera and not a 360-degree camera, neither the above recall nor this one apply to you, but it's probably better safe than sorry here. There are 354,330 crossovers covered by this action. A video output issue could cause the displayed image to cut out, increasing the chances of a reversing accident. Ford will notify dealers starting October 7, the fix being to have a dealer update the Image Processing Module software. The NHTSA campaign number for this recall is 21V735, Ford’s internal reference number is 21S44.  The F-250 and F-350 Super Duty are in for another recalls thanks to potentially improper welds on the front axle's wheel end yoke. A bad weld could alter steering performance, getting the truck to pull left or right, or change the sensitivity of the steering. There are 9,628 affected trucks in the U.S. and 961 in Canada. Dealers will replace the axle assembly if any bad welds are found. Ford's reference number for this is 20S56. The fourth recall affects 38,005 Mustangs in the U.S. and another 2,873 Mustangs in Canada and Mexico from the 2020 model year. In this instance, the brake pedal bracket might fracture during sudden stopping, which can decrease brake pressure and increase the chances of an accident. Ford's internal reference for this recall is 20S52, the fix being to have a dealer replace the brake pedal bracket assembly. Finally, 126,033 units of the 2011 to 2013 Explorer are being recalled over a potential suspension issue.