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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.

Weekly Recap: Racing legend Jim Hall explains Chevy's futuristic Chaparral concept

"I said our cars are built to be winners." – Jim Hall Racing legend Jim Hall never thought he'd be a video game consultant, but when Chevrolet asked for his advice to create a futuristic Chaparral for the Vision Gran Turismo series, he was eager to help. He reviewed early sketches and suggested some changes that made it onto the concept, including the addition of a camera that's mounted onto a mast over the cabin to aid the driver. The Chevy Chaparral 2X Vision Gran Turismo concept was revealed this week at the Los Angeles Auto Show and will be part of a downloadable update for PlayStation 3's Gran Turismo 6 in December. Theoretically, at least, it uses a laser-beam propulsion system and an air-powered generator to produce 900 horsepower in the video game. It's capable of sprinting to 60 miles per hour in 1.5 seconds en route to a top speed of 240 mph. Those gaudy performance specs – even in the virtual world – came at Hall's urging. "I said our cars are built to be winners," Hall told Autoblog on the floor of the Los Angeles show. The 79-year-old drove Lotus racecars in Formula One before launching the successful Chaparral Cars in the 1960s. Like his innovative Can-Am racers, the Vision Gran Turismo project has an eye toward the future. It also introduces the iconic Chaparral name to a new generation of fans, and hopefully, Hall says, gets them excited about engineering and design. "It emulates what we did in the '60s," he said. And what they did back then still resonates. Chaparral Racing and Chevy partnered more than 45 years ago for development work on the composite monocoque chassis, lightweight alloy powertrains, automatic gearboxes and active aerodynamics. "He [Hall] walked right back into this and was able to apply thinkings and learnings," said Clay Dean, General Motors executive director of advanced design. The Chevy Chaparral 2X Vision Gran Turismo concept was created at GM's North Hollywood advanced design studio, and it will be on display at the show through November. Other News and Views Sebastian Vettel joins Ferrari team in 2015 Ferrari confirmed that four-time Formula One World Champion Sebastian Vettel will join the Scuderia for the 2015 season, jettisoning Ferrari's current ace, two-time champ Fernando Alonso. Vettel has been F1's most successful driver since Michael Schumacher, though he's struggled to match his previous accomplishments in 2014.

May 2016: FCA wins, Ford and GM stumble on weak car volumes

The May 2016 sales numbers are in, and it looks as though FCA is getting some vindication for boldly cancelling two slow-selling car models. Meanwhile, Ford saw overall sales dip and GM's May volume took a big dive versus the same month in 2015. While Marchionne's decision to axe the Chrysler 200 and Dodge Dart has drawn criticism as being short-sighted, it's working for FCA so far. Although the Dart and 200 aren't out of production yet and no capacity has been shifted to crossover or trucks, May's numbers show that the emphasis on Jeep and Ram models makes sense right now. FCA's US sales rose 1 percent last month compared to May 2015, putting the year-to-date total at 955,186 vehicles, an increase of 6 percent compared to the same period last year. Standouts included the Jeep Renegade, Compass, and Patriot, and the Fiat 500X. Ram pickup sales were down 3 percent. And your fun fact is that Alfa Romeo sales were up precisely 10 percent, for a total of 44 4Cs sold versus 40 in the same month last year. At FoMoCo, the Ford brand took a hit to the tune of 6.4 percent from May 2015 to 2016, registering 226,190 sales last month. Lincoln showed improvement on its modest numbers, going from 9,174 to 9,807, a 6.9 percent increase. Overall, Ford was down 5.9 percent for the month to 235,997; despite the slump, year-to-date total Ford sales are up 4.2 percent to 1,112,939. Strong sellers included Escape, Expedition, F-Series, and Transit - big stuff. Most small and/or efficient models (Fiesta, Focus, Fusion, C-Max) saw sales slides. Fusion sales were also down, likely due to effects of model changeover to the freshened 2017 model. Ford has promised four new crossovers and SUVs by 2020 and if things keep trending this way the company will be able to sell them, but things could change in the next four years. GM saw the worst of it for domestic brands. Retail and fleet sales were down for each of the four divisions, with the May 2016 total dropping 18 percent to 240,450 vehicles. GM's year-to-date sales are down 5.0 percent in 2016 to 1,183,705. Both the Sierra and Silverado were down significantly, and the majority of Chevy, Buick, GMC, and Cadillac nameplates saw sales decreases, with both small cars and larger utilities included. Not even big stuff could help GM this month, it seems. We'll have more on the rest of the industry's May sales as those figures trickle in.