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NHTSA advances investigation of Ford Crown Victoria headlights

The National Highway Traffic Safety Administration is opening a preliminary evaluation into reports of suddenly failing headlights on 517,945 examples of the 2003-2005 Ford Crown Victoria and Mercury Grand Marquis. The government started looking into this problem in April when the North Carolina Consumers Council filed a defect petition with the agency. Now, the inquiry has moved to the next step. According to NHTSA's documentation (as a PDF), it examined its own database and worked with Ford to come up with a total of 3,609 complaints of the front lighting control module suddenly failing. When this happens, drivers lose the low-beam headlights, but the high-beams can be used by holding the stalk. Sometimes turning the switch off and on fixes the issue. Additionally, there are 15 allegations of crashes, and one reported shoulder injury. NHTSA's preliminary evaluations "evaluate the scope, frequency, and consequence of the alleged defect" and don't necessarily lead to a recall. NHTSA looked into this problem once before in 2008 and 2009 and decided that a recall wasn't necessary. Ford also extended the warranty on the front lighting control module for these vehicles. INVESTIGATION Subject : Loss of headlights Date Investigation Opened: AUG 10, 2015 Date Investigation Closed: Open NHTSA Action Number: PE15028 Component(s): EXTERIOR LIGHTING All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD CROWN VICTORIA 2003-2005 MERCURY GRAND MARQUIS 2003-2005 Details Manufacturer: Ford Motor Company SUMMARY: After receiving a defect petition (DP15002) concerning the loss of headlights and other exterior lighting in model year (MY) 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles, the Office of Defects Investigation (ODI) analyzed Vehicle Owner Questionnaire (VOQ) complaints received from consumers and identified a total of 605 reports (for all submission dates) alleging headlight failure. The complaints indicate failures of both low beam headlights typically while driving, a defect condition that was evaluated under a prior ODI investigation (PE08066). Most consumer VOQs indicate that the headlights failed suddenly and without warning leaving the driver with no forward lighting, however some report the headlights flickered or dimmed prior to turning off. In some cases drivers were able to turn the headlights back on after a period of time while others reported the headlights would not come back on at all.

Junkyard Gem: 1993 Mercury Topaz GS Sedan

As long as the Mercury brand existed — a period spanning the 1939 through 2011 model years — nearly every Mercury sold in the United States was more or less a redecorated Ford model. The Torino had its Montego sibling, the Crown Victoria had the Grand Marquis, the Cougar was based on everything from the Mustang to the Mondeo, and so on. Naturally, when the folks in Dearborn developed the Ford Tempo compact, a Mercury version had to be created. This was the Topaz, with the official launch of both cars taking place on the deck of the aircraft carrier often referred to as the USS Decrepit. You can't make this stuff up! The Tempo/Topaz, also known as the Tempaz, has largely faded from our collective automotive memory by now, since it broke no significant new engineering or styling ground (this story would be much different if Ford had only put the amazing straight-eight "T-Drive" Tempaz powertrain into production) and didn't have any endearing features other than being a cheap domestic competitor to the Toyota Corolla and Nissan Sentra. Still, close to 3 million Tempazes left North American Ford and Lincoln-Mercury showrooms during the 1984-1994 period. As you'd expect, most of these disposable cars disappeared from both the street and the car graveyard long ago. It takes a very special Tempaz for me to break out my camera while I'm patrolling my local wrecking yards; generally, this means an ultra-rare all-wheel-drive version or at least a very early model in super-clean condition. Today's Junkyard Gem is neither, but I took one look at this spectacular Bordello Red crypto-velour-and-slippery-plastic interior and recognized that this was no ordinary junkyard Mercury. It appears that Mercury had dropped the idea of clever names for base-grade seat fabrics by the time of the Topaz, referring to this stuff as just "cloth" in all the brochures I could find. That's too bad, because Mercurys had cool names for upholstery (e.g., Chromatex) in the old days. The interior is in very good condition but the steering wheel shows substantial wear, so I think this is a high-mile Topaz that got meticulous care from its owner or owners. Ford used five-digit odometers on these cars until the end of production, however, so we'll never know if this reading indicates 65,404 miles or 365,404 miles. The body is very straight, but there's some nasty corrosion behind the right front wheelwell.

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.