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Ford recalls 434k vehicles for several unrelated issues

It seems that the hard winter in much of the country has been as rough on some Fords as it has on many people. The Blue Oval is recalling roughly 434,000 vehicles in two separate recalls, and one of them partially caused by the salt used to melt the snow on roads.
The first recall covers 385,750 2001-2004 Escape models in the Midwest, Northeast and Canada because a subframe could rust and eventually fail. This is partially due to the road salt used in those areas, and about 349,000 of the affected vehicles are in the US. To remedy the problem, dealers are installing a reinforcement cross brace on the frame to strengthen them. There has been one crash caused by the failure but no injuries. According to The Detroit News, this is not the first rust-related recall for Ford. It estimates the company has repaired over two million vehicles since 2010 for problems on vehicles related to the iron oxide, including the rear wheel wells of the Freestar minivan.
The second recall covers 48,950 2013-2014 Ford Fusion, Escape, C-MAX and Lincoln MKZ models because welds in their seatbacks don't meet National Highway Traffic Safety Administration standards. The fault affects the front seats, and the sub-standard welds joining the setback to the recliner could increase the chance on injury. There have been no reported injuries or accidents caused by the problem, but there are 42,972 affected vehicles in the US and 4,744 in Canada.

Ford Announces Four Recalls, 1.4M Vehicles Affected

Ford is taking a bit of the spotlight away from General Motors, announcing a major group of recall campaigns, covering a total of 1.4 million vehicles built between 2006 and 2013. Let's start with the big one, which covers the Ford Escape, Mercury Mariner and, according to The Detroit News, Ford-built Mazda Tribute CUVs. 915,216 vehicles are covered, all of which were built in model years 2008 to 2011. 736,000 vehicles are in the US, while Canada then Mexico make up the vast majority of the remainder. The problem is due to an issue with the torque sensor in the steering column, which could lead to sudden power steering failure. Manual steering would still be available, though. "Dealers will perform one of three service fixes, depending upon what diagnostic codes are shown when the vehicle is taken to the dealer," Ford spokeswoman Kelli Felker wrote to Autoblog in an email. "They will either update software for the power steering control module and the instrument cluster module; replace the torque sensor; or replace the steering column, which includes upgraded power steering control module software." The most recent generation of the Ford Explorer is suffering from a similar malady, thanks to an intermittent electrical connection (we think that means short circuit) in the steering column. Like the Escape and Mariner, manual steering would still be available in the event of a power failure. Ford will recall 195,527 examples of its Explorer, 177,500 of which are in the US. This recall covers model years 2011 to 2013. According to Automotive News, the National Highway Traffic Safety Administration has stated that Ford will inform owners of affected vehicles by July 25. Ford is also recalling 200,000 Taurus sedans, over a corrosion issue in the license plate lamp. This particular recall, which covers vehicles from model years 2010 to 2014, is limited to drivers in northern climes. Vehicle owners in southern states are free to pass on the recall. Finally, 82,576 Fusion, Mercury Milan and Lincoln Zephyr/MKZ sedans from 2006 to 2011 are being recalled because of floormats that can interfere with the accelerator pedal. Dealers will replace the offensive floormats with newer examples. "Ford is committed to providing our customers with top quality vehicles. We are equally committed to addressing potential issues and responding quickly for our customers," Felker wrote.

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.