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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.

Which is more fuel efficient, driving with a pickup's tailgate up or down?

Thanks to the smoke wand in the wind tunnel, you can actually see the difference in our video.
Should you drive with your pickup truck's tailgate up or down? It's an age-old controversy that's divided drivers for decades. Traditionalists will swear you should leave the tailgate down. Makes sense, right? It would seem to let the air flow more cleanly over the body and through the bed. But there's also a school of thought that argues trucks are designed to look and operate in a specific manner, and modern design techniques can help channel the airflow properly. So don't mess with all of that: Leave the tailgate up.

Ford Focus was best-selling nameplate in 2012

Last August, Ford made a few waves by claiming that the Ford Focus was, at that point, the top-selling car in the world. The automaker failed to account for variations of the Toyota Corolla wearing a different name (such as the Auris and Matrix), however. With official data from Polk coming in now, Ford is able to say that the Focus was, in fact, the best-selling nameplate in the world last year.
Using new-car registrations (which doesn't factor in fleet sales), the Polk data shows that a total of more than one million Focus models around the world. Strong sales in the US and China have led to a 16 percent increase in year-over-year Focus sales from 2011 that helped to create even more of a gap between it and the second-best global seller, the Corolla.
Ford also had the Fiesta and F-Series listed in the top 10 for worldwide nameplates, but what's even more impressive is the fact that the F-Series is only sold in North America. Scroll down to see the list (compiled by Ford using Polk data) of the top global sellers last year and a press release from Ford.