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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.

Monochromatic Package spreads to Lincoln's Corsair, Nautilus, and Aviator

Lincoln is catering to buyers seeking a mostly chrome-free SUV by making the optional Monochromatic Package available on the Corsair, the Nautilus, and the Aviator. It was inaugurated by the Navigator in 2019. Inspired by current trends in fashion and interior design, the Monochromatic Package bundles a darker grille, tinted emblems, body-colored mirrors, and darkened trim pieces all around. It also includes black 20- or 22-inch alloy wheels, depending on the model. Lincoln made no mention of modifications in the cabin. 2021 Corsair and 2021 Aviator buyers who tick the Monochromatic Package box will be asked to choose from three colors named Pristine White, Infinite Black, and Asher Gray, respectively. The Monochromatic-equipped 2020 Nautilus will exclusively be offered in Infinite Black, while the 2020 Navigator carries on with Pristine White, Ceramic Pearl, and Infinite Black as its color options when buyers add the package. Lincoln hopes expanding the Monochromatic Package's availability will allow its SUVs to keep building momentum, but pricing information hasn't been announced yet. For context, the chrome-free look costs $3,495 on the 2020 Navigator, and it's exclusively offered on the mid-range Reserve model priced at $83,665. Like parent company Ford, Lincoln is increasingly reliant on its crossovers and SUVs. It confirmed its last two sedans, the MKZ and the Continental, will retire without a replacement in sight after the 2020 model year.

Ford rethinking vehicle launch strategy

With a new boss at the helm, Ford is looking at new ways to improve its vehicle launches in North America to prevent recent issues that have popped up with models like the Lincoln MKZ, Ford Escape and Ford Fusion. Speaking with Automotive News, Ford's new president of the Americas, Joe Hinrichs, revealed a few ways the automaker plans to avoid early build issues such as the engine fires on certain 2013 Escape and Fusion models and months-long delays for customers to receive their MKZs.
It sounds like the root of the problems may have been Ford's relationship with suppliers compounded by the fact that the product surge came on the heels of the recent industry-crippling recession, and in the AN article, Hinrichs says improvements are being made to reduce problems during the launch of new or redesigned models. Three such improvements that were implemented during the first quarter of this year including more rigorous quality comparisons, better use of computer technology to catch major problems sooner and hiring engineers to work closer with suppliers.