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How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.

Spy shooter claims proof of upcoming aluminum Ford F-Series Super Duty

Ford has already confirmed that the 2015 F-150 (pictured above) was just the beginning for its more extensive use of aluminum. CEO Alan Mulally said it himself during the 2014 Detroit Auto Show. We've even already seen the future Raptor testing with an aluminum body. But a recent discovery from an intrepid spy photographer might indicate that the lightweight metal is coming to the Blue Oval's Super Duty pickups in their upcoming generation, as well.
According to Automotive News, a spy shooter in Colorado spotted a prototype for the next-gen F-350 testing. He happened to have a magnet on hand and got close enough to check the truck out. When he held it up to the metal in the bed, it didn't stick, which signaled to him a switch from steel to aluminum.
Obviously, this claim raises some questions. Given that it was a test vehicle, one possibility is that the Blue Oval is just evaluating the feasibility of switching to aluminum for the Super Duty trucks, not necessarily committed to it yet. Ford has been testing it quite exhaustively, after all. In fact, much of the rest of the truck in question was covered in camouflage, so it's possible that the magnet failed to work along the rest of the body not because it was aluminum, but because it wasn't powerful enough to get through the disguising material. Thus, the lightweight metal's use could be far less substantial than on the new F-150. Still, it was a clever idea for the cameraman to check things out and might have given us the first hint about brand's next heavy-duty models.

Ford issues six recalls covering 101,000 vehicles for multiple issues

Ford is announcing six separate recalls for a variety of issues affecting a dozen models and a total of 100,610 vehicles in North America. However, according to Ford spokesperson Kelli Felker, "None of them have caused accidents or injuries." Half of them cover fewer than 1,000 cars.
The largest recall covers 92,022 North American examples (about 83,250 in the US) of some models of the Ford Taurus, Lincoln MKS, Ford Interceptor, Flex and Lincoln MKT from the 2013 and 2014 model years; the 2012-2014 Edge and the 2014 Lincoln MKX. All of them have a potential issue with the halfshaft on the right side that might not be fully seated and could move outward over time. If it shifts too far, the models may no longer be able to drive, and the condition could also allow the vehicles to roll away, even when in Park. Dealers will inspect the shaft to make sure it's seated and will replace the part if necessary.
The next-largest recall covers 5,264 North American examples (4,867 in the US) of the Ford F59 Commercial Stripped Chassis from the 2011-2014 model years. It's possible that an electrical junction box can corrode in areas with salty roads and short circuit. The problem could potentially cause a fire. Dealers will replace the box with an improved design.