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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.

Ford adds 850 jobs to build 2015 F-150

Pickup trucks tend not to advance at quite the same pace as the rest of the industry. That's what makes the new Ford F-150 so remarkable, jettisoning its old steel construction in favor of aluminum. It's a game changer that Ford is betting big on, and in anticipation of surging demand, the Blue Oval automaker is adding 850 new jobs to put the thing together.
Those 850 new employees will be centered at Ford's Rouge complex in Michigan - with 300 at Dearborn Stamping, 50 more at Dearborn Diversified and 500 at the Dearborn Truck facility, the latter of which has already kicked off what Ford describes as "the largest manufacturing transformation in decades." Old manufacturing equipment is being replaced with the latest technologies, and even the Ford Rouge Factory Tour is undergoing a complete overhaul.
The new jobs come as part of the commitments Ford made to the UAW in 2011 to create 12,000 hourly jobs in the United States by 2015 - a number which Ford has already exceeded at 14,000. Over 4,000 of those are centered in southeastern Michigan.

Ford Mustang, F-150, Expedition, and Lincoln Navigator recalled

The Basics: Ford will recall 201,900 examples of the 2011-2012 F-150, 2012 Expedition, 2012 Mustang, and 2012 Lincoln Navigator. The affected vehicles have the 6R80 transmission. Of the total, there are 84,000 of them in the United States and 17,900 in Canada. The Problem: The output speed sensor on the vehicle's transmission lead frame can force the gearbox to downshift into first gear. If this happens at high speed, it could cause the rear tires to slide or lock up. Injuries/Deaths: There are no reported injuries, but Ford know of three accidents related to this problem. The Fix: Dealers will update the powertrain control module software to eliminate the problem, and they'll also replace the transmission lead frame. If You Own One: Ford will begin notifying affected customers by mail on May 23. Related Video: FORD MOTOR COMPANY ISSUES THREE SAFETY RECALLS AND TWO SAFETY COMPLIANCE RECALLS IN NORTH AMERICA DEARBORN, Mich., April 27, 2016 – Ford Motor Company is issuing three safety recalls and two safety compliance recalls in North America. Details are as follows: Ford issues safety recall and customer satisfaction program for certain 2011-2012 Ford F-150, and 2012 Ford Expedition, Ford Mustang and Lincoln Navigator vehicles in North America to update powertrain control module software and inspect for certain diagnostic trouble codes Ford is issuing a safety recall for approximately 202,000 2011-2012 Ford F-150, and 2012 Ford Expedition, Ford Mustang and Lincoln Navigator vehicles for a potential issue with the output speed sensor on the vehicle's transmission lead frame. Under certain conditions, the transmission controls could force a temporary downshift into first gear. Depending on the speed of the vehicle at the time of the downshift, the driver could experience an abrupt speed reduction that could cause the rear tires to slide or lock up. This condition could result in loss of vehicle control, increasing the risk of a crash. Ford is aware of three reports of accidents and no injuries related to this condition. Affected vehicles are equipped with a 6R80 transmission and include certain 2011-2012 Ford F-150 vehicles built at Dearborn Truck Plant and Kansas City Assembly Plant, Aug. 19, 2011 through March 9, 2012; 2012 Ford Expedition vehicles built at Kentucky Truck Plant, Aug. 19, 2011 through Dec. 19, 2011; Ford Mustang vehicles built at Flat Rock Assembly Plant, Aug. 19, 2011 through Feb.