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Ford finds flex-fuel engine design plays big role in emissions output

How bad is ethanol for your engine? There's been a lot of debate on this issue as the US considers upping the biofuel content in the national gasoline supply from 10 percent (E10) to 15 percent (E15). The ethanol industry and some scientists say higher ethanol blends show no "meaningful differences" in new engines while the oil industry says ethanol creates health risks. Researchers working at the Ford Research and Innovation Center decided to take a closer look at how a wide range of gas-ethanol blends - E0, E10, E20, E30, E40, E55 and E80 - affected the emissions coming out of a flex-fuel 2006 Mercury Grand Marquis. To see the full report, printed in the journal Environmental Science & Technology, requires payment, but there is an abstract and Green Car Congress has some more details. The gist is that, "with increasing ethanol content in the fuel, the tailpipe emissions of ethanol, acetaldehyde, formaldehyde, methane, and ammonia increased." At least NOx and NMHC emissions decreased. The researchers say that the effects are due to the fuel and "are expected for all FFVs," but that the way that a manufacturer calibrates the engine will affect NOx, THC, and NMOG emissions. It's this last bit that's important, since the researchers found, "Higher ethanol content in gasoline affects several fundamental fuel properties that can impact emissions. ... These changes can have positive or negative effects that can depend on engine design, hardware, and control strategy. In addition to direct emissions impacts, higher ethanol content fuel can also provide more efficient combustion and overall engine operation under part-load conditions and under knock-limited higher-load conditions." So, as we head towards more ethanol in our fuel supply (maybe), manufacturers are going to need to learn how to burn it most efficiently.

Ford and Chrysler reducing summer plant shutdowns

Most domestic automaker assembly plants traditionally take a couple of weeks off during the summer. The shutdowns give each plant time for much needed repairs and maintenance, and in some cases, help better align production with demand. Not this year, though, as demand for many models is outstripping what Ford, Chrysler and General Motors plants can produce.
Ford has announced that it will shorten its annual summer shutdown for most North American plants from two weeks to one. The shorter shutdown will increase the carmaker's annual North American production by 40,000 units on top of the 200,000 extra units that it was already planning to produce this year versus last. Automotive News reports that Ford produced 2.8 million vehicles on this continent in 2012, and that output this year has already increased 13 percent through April.
Chrysler, meanwhile, is also operating at full tilt and plans to run some plants through the summer with no shutdown at all. Those not getting a break include Jefferson North where the Jeep Grand Cherokee and Dodge Durango are assembled, Toledo North that will assemble the new Cherokee, and Conner Avenue, home of SRT Viper production. Other assembly plants will be down for a single week, while all of Chrysler's engine and transmission plants except one in Indiana will continue operating with no shutdown this summer.

2013-2017 Ford Explorer recalled over rear suspension issue, again

Ford is recalling about 375,000 Explorer SUV models built between 2013 and 2017 in North America to fix a potential defect in the rear suspension. In "North America states and provinces where corrosion is common," which we take to mean areas that experience harsh winters and heavily salted roads, "a fracture of the outboard section of the rear suspension toe link" is possible on affected vehicles. Ford says 350,000 of these models were sold in the United States and another 25,200 in Canada. This isn't the first time Explorers of this generation have been recalled for fractured toe links. Back in the summer of 2017, 1.2 million Explorer models were recalled over toe links that could fracture if subjected to "frequent full rear suspension articulation (jounce and rebound)." A little over a year earlier, 75,000 Explorers were recalled over, you guessed it, rear toe links that may not have been welded properly. It's not just Explorers that Ford has recalled over rear toe links. Earlier this year, the automaker issued a recall that covered nearly 230,000 Ford Flex, Taurus and Lincoln MKT models. All of these recalled vehicles ride on similar unibody underpinnings that Ford calls the D4 platform. We can't say whether these other D4-based vehicles will get another recall as the Explorer has. Ford says it is aware of as many as 13 crashes and six injuries attributable to the toe links covered under this most recent Explorer recall. Owners will need to visit their preferred dealership, which will "complete a torque inspection of the cross-axis ball joint and replace it as necessary," according to Ford. Related Video: