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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.

Plug In 2014: ALTe ready to join Ford's EQVM to convert, sell F-150 PHEV [w/video]

It's been a while since we've checked in with ALTe and its plans to convert big work vehicles like the Ford F-150 into plug-in hybrids. So, when we saw a demonstration vehicle sitting outside the San Jose Convention Center at the Plug In 2014 Conference last week, we had to get a closer look. When we did, we realized that it's been quite some time since we've been in a Ride & Drive vehicle that was all beat to heck. It's been quite some time since we've been in a Ride & Drive vehicle that was all beat to heck. The reason for the well-worn F-150 with 30,000 miles on it is that ALTe has been showing off its extended-range EV technology to lots of people all around the country, and Kyle Maki has been the man on the scene more often than not. "This one, I've taken all over the country," he told AutoblogGreen. "I've wore out that seat, I think. The only reason this one wasn't driven here was because we were in Charlotte [NC] last week and I didn't want to take a chance and not make it in time for this event." In other words, ALTe is out there, ginning up excitement for the idea of a plug-in hybrid Ford with an electric range of up to 40 miles and which can then continue on gas for another 360 miles at around about 25 miles per gallon. ALTe wants to not only convert new vehicles but it also offers retrofits for fleets that are happy with their current fleet. The company offers converted versions of the Ford E350 and E450 utility vehicles now but the near-mythical F-150 PHEV is still "coming soon." Yes, orders are now being accepted, but you will be forgiven if you think this is all happening on a slow time scale. There are simply a lot of things to do before ALTe can sell the truck. ALTe is currently attempting to join Ford's EQVM program, which is the electric version of the standard Qualified Vehicle Modifiers program. The QVM program requires coachbuilders to "be successfully evaluated by Ford Motor Company on criteria such as engineering, the manufacturing process, quality control, and adherence to Ford and Lincoln Divisions guidelines." Qualified applicants must also meet all applicable Federal Motor Vehicle Safety Standards, conform to Ford/Lincoln conversion guidelines and agree to be inspected annually as well as have a "commitment to continuous improvement." Maki has a simpler explanation. "It basically means you're a preferred supplier, a Tier 1, if you will," he said.

Did a US automaker blow the whistle on Hyundai, Kia fuel economy issue?

In all of the most hotly contested mainstream segments of the motoring universe, the difference of one mile per gallon averaged on a widow sticker can mean the difference between a sale and a walk-off - to say nothing of two or three mpg. So, when Hyundai and Kia were forced to reveal that many of their 40-mpg ratings were actually 38s and 37s, well, it made for big news.
It also, conceivably, made for a competitive disadvantage immediately, when the Korean automakers' products were being shopped versus the guys down the block. And it's that disadvantage that makes a recent story from Automotive News so juicy.
AN is reporting that Margo Oge, former head of the Environmental Protection Agency's Office of Transportation and Air Quality, got a tip in 2010 that Hyundai/Kia were "cheating" to get its impressive fuel economy numbers. The tip, said Oge (who retired from the EPA this past September), came from a senior vice president from a domestic automaker. The source was credible enough for Oge to launch an audit of the Hyundai figures, which ultimately lead to the debacle that we reported on a few months ago, and that the Korean company has been trying to bounce back from ever since.