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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.

Here are a few of our automotive guilty pleasures

It goes without saying, but I'll say it anyway. The world is full of cars, and just about as many of them are bad as are good. It's pretty easy to pick which fall into each category after giving them a thorough walkaround and, more important, driving them. But every once in a while, an automobile straddles the line somehow between good and bad — it may be hideously overpriced and therefore a marketplace failure, it may be stupid quick in a straight line but handles like a drunken noodle, or it may have an interior that looks like it was made of a mess of injection-molded Legos. Heck, maybe all three. Yet there's something special about some bad cars that actually makes them likable. The idea for this list came to me while I was browsing classified ads for cars within a few hundred miles of my house. I ran across a few oddballs and shared them with the rest of the team in our online chat room. It turns out several of us have a few automotive guilty pleasures that we're willing to admit to. We'll call a few of 'em out here. Feel free to share some of your own in the comments below. Dodge Neon SRT4 and Caliber SRT4: The Neon was a passably good and plucky little city car when it debuted for the 1995 model year. The Caliber, which replaced the aging Neon and sought to replace its friendly marketing campaign with something more sinister, was panned from the very outset for its cheap interior furnishings, but at least offered some decent utility with its hatchback shape. What the two little front-wheel-drive Dodge models have in common are their rip-roarin' SRT variants, each powered by turbocharged 2.4-liter four-cylinder engines. Known for their propensity to light up their front tires under hard acceleration, the duo were legitimately quick and fun to drive with a fantastic turbo whoosh that called to mind the early days of turbo technology. — Consumer Editor Jeremy Korzeniewski  Chevrolet HHR SS: Chevy's HHR SS came out early in my automotive journalism career, and I have fond memories of the press launch (and having dinner with Bob Lutz) that included plenty of tire-smoking hard launches and demonstrations of the manual transmission's no-lift shift feature. The 260-horsepower turbocharged four-cylinder was and still is a spunky little engine that makes the retro-inspired HHR a fun little hot rod that works quite well as a fun little daily driver.

Ford announces fix for 2021 Expedition and Lincoln Navigator fires

In the middle of May, Ford announced a recall of around 39,000 Ford Expeditions and Lincoln Navigators from the 2021 model year due to fires starting under the hoods of the SUVs. At the time, Ford had received 16 incident reports, 14 of them happening with rental vehicles. The automaker cautioned owners to park their vehicles outside and away from structures while engineers figured out what was happening and how to fix the problem. Since that May announcement, five more fires have been reported, four of them rental vehicles, and there's been one burn injury. The company announced it understands the problem and has a fix, at the same time widening the scope of potentially affected vehicles. Instead of recalling 39,013 units built between December 1, 2020, and April 30, 2021, the recall now includes 66,221 vehicles assembled from July 27, 2020, to Aug. 31, 2021. The suspected culprit is a circuit board provided by a supplier that changed manufacturing location during the pandemic. Ford's press release on the matter stated that "circuit boards produced at this facility are uniquely susceptible to a high-current short." The affected vehicles are fitted with either an 800-watt or 700-watt cooling fan system. About a third of the recalled population are fitted with the former, and should get a quick fix at the dealer. On these SUVs, techs will inspect the battery junction box. If they find evidence of melting, they'll replace the whole box. If not, they'll simply remove the engine fan ground wire that runs to the battery junction box; since this ground relay is redundant, the change doesn't alter operation of the fans.  Owners with the 700-watt system might need to wait until September for a fix. These vehicles need an auxiliary relay box with a wire jumper, but the parts aren't available now.   Ford's notifying all owners via the FordPass app, and will follow up with owners of the 700-watt cooling system once the parts are in stock. Until their vehicles are fixed, Ford says the SUVs are safe to drive but that they should still be parked outside and away from structures. The somewhat mixed messaging — 'Yes, your cars are safe to drive, but they could catch fire so don't park them near anything flammable' — encouraged a group of owners to file suit against Ford. Owners with questions can contact Ford customer service at 866-436-7332 and reference recall No. 22S36.