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Ford recalls 382k vehicles across six campaigns

Ford needs to repair a total of 381,633 vehicles in North America across six newly announced campaigns, including five safety recalls and one compliance recall. By far the largest of these campaigns covers the 342,271 examples of the 1998-2003 Windstar to double check an earlier recall repair. Among these, 283,413 are in the US and 58,858 are in Canada. The combination of corrosion and stress can cause cracks in the rear axle and eventually lead to the part to snap completely. The company reports a small number of accidents might be connected to this, but there are no injuries. The minivans were recalled for this issue back in 2010, and it was investigated by NHTSA. According to Ford's latest announcement, the reinforcement brackets on some of these models might not have been installed correctly. This time, dealers will perform an inspection. Minivans with incorrectly installed brackets will get a new rear axle. The rest of the owners will be offered a deal to replace the part at a reduced cost. The next largest campaign covers 36,857 examples of the 2015 F-150 to fix a problem with the adaptive cruise control. Specifically, there are 33,481 affected trucks in the US, and 3,376 in Canada. According to Ford, "when passing a large, highly reflective truck" the radar in the system can misidentify a semi as being in the same lane as the pickup. The collision warning system would then activate, slowing the F-150. There's one report of an accident with this happening but no injuries. The fix is simply an update to the adaptive cruise control module software. Ford also has a recall for 1,477 examples of its 2016 F-53 and F-59 stripped chassis models, and they're all located in the US. A manufacturing issue might allow the trucks to shift into reverse without the driver first applying the brakes. There are no reports of any accidents from this, though. To repair the problem, the models get a new transmission shift control bracket and an adjustment to the shift cable. The Blue Oval's safety compliance recall covers 708 examples of the 2016 Fusion and Lincoln MKZ, including 658 of them in the US, 28 in Canada, and 22 in Mexico. On these models, a manufacturing problem with the fuel tank could allow it to crack in a crash, which isn't allowed under federal rules. There are no reports of accidents, injuries or fires. The fix will be a new fuel tank for all of them. The company is also repairing 251 units of the 2015 Taurus and Lincoln MKS, plus the 2016 Explorer.

2015 Ford Mustang prototype spotted on the street

Our trusty spy photographers have snapped the first photos of the 2015 Ford Mustang prototype out on public streets. With nearly every square inch of the machine covered in heavy camouflage, it's difficult to discern details, but we can see smallish horizontal headlamps at work in the coupe's nose. Ford has made it clear that modern lighting technology will allow the company to get away from large, expensive headlamp arrays in the near future, and the 2015 Mustang may very well be the first of the automaker's products to bow with the new tech. The philosophy was first displayed on the very attractive Evos Concept.
The extensive cladding doesn't extend all the way to the prototype's rockers in the instance, giving us a look at the heavily-sculpted sills. Overall, this test car looks considerably smaller than the current generation Mustang, and elements like a short front overhang and beefy dual-piston calipers give us plenty of hope for the future model. Of course, reports that the 2015 Mustang will bow with an independent rear suspension and EcoBoost power certainly don't hurt our feelings, either.

Ford reveals new rapid prototyping and low-volume production techniques [w/video]

It's called "F3T," and that stands for Ford Free-form Fabrication Technology. The process that The Blue Oval has developed means being able to sidestep the weeks-long process of tool-and-die making when engineers want to construct a new part, allowing them to fabricate a three-dimensional part from a two-dimensional sheet of metal in just hours.
While F3T is being developed it is limited to "low-volume prototyping or even low-volume niche vehicles," but the next step is to evaluate it for use in Ford's global manufacturing facilities. You can find out more about it in the video and the press release below.