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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.

Swedish car mag says Ford Mondeo is dangerously, illegally overweight [w/video]

Sweden's Teknikens Varld has a reputation for being very persnickety when it comes to auto safety testing, and its latest catch is the Mondeo Titanium Estate 2.0 TDCi 150 bhp S6 MPS (basically a station wagon variant of the Fusion). In addition to the model's mile-long name, it has another problem according to the Swedes, because its weight on the scales does not equal the official numbers for the vehicle. Teknikens Varld claims the wagon is dangerously overweight because it weighs in 4,145 pounds, while Ford officially lists its weight at 3,530 pounds. That 615-pound disparity means that if a family loads it to what they think is the model's gross vehicle weight, it will actually be too heavy, and therefore illegal to drive in Sweden. According to the magazine, when it tried doing this, the rear wheels scraped against the wells, and the estate failed the mag's legendary moose test. However, at 220 pounds over the limit, it passed the test. When reached for comment by Autoblog, Jay Ward, Senior Manager at Ford of Europe Product Communications, explained the reason for the deviation between the official numbers and the magazine's test: "We are aware of this, but this is not an issue that relates specifically to the safety of the Mondeo, but is in fact related to the way in which the cars are tested by the authorities. We provided an Ambiente model for the testing but the car that featured in the magazine test was a Titanium model which has a different weight. We are in discussion with the Swedish Transport Agency to change the framework so the real weight of the Titanium model is reported instead of the Ambiente model which will resolve the issue." Teknikens Varld is well-known for calling out automakers for perceived transgressions. Most recently it leveled criticisms against the all-wheel drive system in the Honda CR-V, and both the Jeep Grand Cherokee and Porsche Macan failed its moose test. Scroll down for the magazine's video of weighing the Mondeo Estate and the model's test results. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. The new Ford Mondeo is dangerously overweight The new Ford Mondeo is a great car, which Teknikens Varld's test shows, but there is one problem – the weight. Mondeo weighs 279 kg more than Ford claims. With big load (ie family plus luggage) the car therefore becomes illegal to drive.

Ford investing $2.5 billion in two new plants in Mexico

Automobile production keeps ramping up in Mexico. Last week alone, Toyota announced a new plant it's building south of the border, and news broke that Hyundai is looking into the same. Now Ford has announced a multi-billion-dollar initiative that will see it building two new facilities in Mexico, as well. Though neither will be a final assembly plant, both promise to break new ground for the automotive industry in Mexico – at least as far as Ford is concerned. The first is a new engine facility to be built at Ford's existing plant in Chihuahua. The fruit of a $1.1-billion investment will see the Blue Oval produce new gasoline engines for use in North America, South America and Asia-Pacific, creating 1,300 new jobs in the process. Ford will also be investing another $200 million to expand its inline-four and diesel engine production lines at the same plant. The move will create another 500 new jobs and make Ford's Chihuahua engine plant the largest in Mexico, according to the company's press release. Ford has also announced the building of its first transmission facility in Mexico, to be constructed within Getrag's plant in Irapuato in the state of Guanajuato. The $1.2-billion investment will create 2,000 new jobs and be charged with exporting two new automatic transmissions to markets around the world. The announcement comes on the 90th anniversary of Ford's presence in Mexico, dating back to 1925. Currently the company produces the Fiesta, Fusion and Lincoln MKZ in Mexico, as well as numerous Duratec and diesel engines. Related Video: FORD ANNOUNCES $2.5 BILLION USD INVESTMENT FOR NEW ENGINE, TRANSMISSION PLANTS IN MEXICO - Ford is investing $2.5 billion USD in new engine and transmission plants in the Mexican states of Chihuahua and Guanajuato, respectively - Approximately 3,800 direct jobs will be generated through three projects – a new engine plant in Chihuahua, expansion of Ford's I-4 and diesel engine lines in Chihuahua and a new transmission plant – Ford's first in Mexico – in Guanajuato - The investment is part of the company's One Ford plan, which emphasizes global competitiveness. The news comes as Ford celebrates its 90thyear in Mexico Further building its lineup of increasingly fuel-efficient engines and transmissions, Ford today announced a $2.5 billion investment in two new facilities building a new generation of engines and transmissions in the states of Chihuahua and Guanjuato, respectively.