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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.

John Hennessey's personal 2015 HPE700 Supercharged Ford Mustang GT hits 195 mph

Dressed in a coat of menacing black paint, the 2015 Hennessey Performance HPE700 Supercharged Ford Mustang GT definitely looks like one mean muscle machine. The 717-horsepower 'Stang proved that it can back up that aggressive appearance recently when company founder John Hennessey took his personal example to see just how fast it would go. The result down the 1.1-mile straight at the Continental Tires Proving Grounds in Uvalde, Texas, was over 195 miles per hour. The Mustang is nothing but a black blur and wall of supercharger wail as it buzzes by the camera at top speed. Despite the strong result, Hennessey doesn't seem done with the 'Stang yet. The car still seems to be pulling when it hits the rev limiter, and there's some straight track left ahead. After getting out, John Hennessey immediately says he thinks 200 mph is possible. The heart of the HPE700 is a 2.9-liter Roots-Type supercharger running at 7.25 psi. That's a pretty massive blower, especially when considering the 2.4-liter unit on the Hellcat V8. The engine also gets upgrades like improved injectors, a new fuel pump, stainless steel exhaust and recalibrated management. The company claims the upgraded Mustang can hit 60 in around 3.6 seconds and do the quarter-mile in 11.2 seconds at 131 mph. Prices for the package start at $59,500, but this one would would ring up for $65,874. Hennessey Performance is limiting production to 500 of them for the 2015 model year. 2015 HPE700 Supercharged Mustang Rockets to 195.2 mph John Hennessey takes his personal Mustang GT on a Texas road trip Uvalde, Texas-Everything is bigger in Texas, especially when it comes to automotive performance. Texas also lays claim to the highest posted speed limit in America at 85 mph. Enter the team from Hennessey Performance Engineering (HPE) who are located just west of Houston. John Hennessey and his merry band of performance car builders like to go fast, so much so that they have their own 1/4 mile dragstrip next to their workshop. Recently, the Hennessey team wanted to test their 717 horsepower HPE700 Supercharged Mustang development car (John's personal car and occasional daily driver) beyond the 130+ mph speeds that they have seen on the dragstrip. "Thankfully, we had recently received an invitation from the guys at the Continental Tires proving grounds in Uvalde to come over and do some testing on their 8.0 mile high speed oval", said Hennessey.

Ford recalls more than 550,000 trucks and SUVs for various safety issues

Ford announced safety recalls for its current F-150 pickup along with several Ford and Lincoln crossovers early Wednesday. The recalls cover more than 550,000 vehicles and address various safety defects, ranging from a fire hazard to potential loss of braking power.  The most far-reaching of the recalls covers approximately 550,000 examples of the 2015-2018 Ford Edge and 2016-2018 Lincoln MKX, which may have been assembled with defective front brake jounce hoses (also commonly referred to as "flex lines"). These hoses run from fixed points on the chassis to the individual front brake calipers. Defective hoses could potentially rupture, allowing brake fluid to leak and resulting in a loss of braking function. Ford will replace the components in question with revised parts.  The next-largest recall is for roughly 3,000 2020 Lincoln Corsair crossovers. The affected models may have been assembled without proper clearance between their rear suspension springs and toe link brackets. The components could potentially make contact, wearing down the protective coating on the rear coil springs, allowing corrosion to occur over time. This corrosion could eventually lead to a failure of the spring. If this happens while the vehicle is being driven, it could result in a sudden change to the vehicle's handling characteristics, and the spring fragments could potentially cause further damage to the car or surrounding traffic.  Ford says owners will be notified that their Corsairs need to be inspected; if there is not adequate clearance between the rear suspension components, Ford's service technicians will remove material from the toe link bracket to allow for operation without contact.  The final (and by far the smallest) recall is for the 2020 F-150. Some units may have left the factory with the incorrect retention nut on the hot lead to the starter motor. Ford says it can cause increased heat generation or electrical arcing, which could potentially result in a fire. Ford says this issue is limited to just a few hundred examples sold in the United States. Dealers will inspect the vehicles and replace the nut if necessary.