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Ford Explorer problems gutted third-quarter sales

In early September, the Detroit Free Press published a feature noting numerous problems Ford's having with the 2020 Explorer and 2020 Lincoln Aviator launches. Issues with both SUVs, built at Ford's Chicago Assembly Plant, were so rife and dire that the automaker was trucking the vehicles 275 miles away to Michigan for repairs. Bloomberg reported earlier this month that Explorer's third-quarter sales dropped 48 percent compared to the previous model in 2018, with dealers unable to get enough units on lots for customers. Nor is the snafu over: Automotive News reports that another "batch of about 2,500 Explorers in need of repairs" arrived recently in Michigan, and sales through the first nine months of 2019 are down 31 percent. Sales dips during model changeovers are to be expected as old inventory gets sold down and new production ramps up, but this is different. Ford U.S. sales boss Mark LaNeve told Bloomberg earlier this month, "We’ve got adequate inventory in our stores. For Q4, availability wonÂ’t be an issue. WeÂ’ll be able to hit our stride with Explorer starting now." It's hard to know whether that's true, with thousands of Explorers still piling into Michigan; the batch AN mentioned represents about 5 days of sales during an average month in 2018, before the drawdown and interruptions hampered matters. And when Consumer Reports tested the Ford Explorer it bought this summer, it titled the review, "2020 Ford Explorer drives nicely but has many flaws / Poor interior quality and a high price overshadow the SUV's improvements."   On top of that, the AN piece mentions a new impediment to uncorking the Explorer sales stream: Worker strife in the Chicago plant. Allegedly, "Roving groups of workers are intimidating other employees, creating a hostile environment, the people said. ThatÂ’s driving up turnover and leaving some vehicle assembly unfinished, contributing to the company having to complete the work at the Michigan factory or at dealerships, the people said." Ford's been fined twice before for the same kinds of issues at its plants, once in 1999, again in 2017, but a spokesperson said Ford isn't aware of any such problems now. The pressure otherwise has got to be unpleasant for everyone on the Explorer team, from CEO Jim Hackett down. The automaker was meant to be "turning the corner" in April, but as of now, shares are down, credit rating is down, earnings are down.

70% of pickups could use aluminum by 2025

In the next decade, the auto industry will see an explosion in its use of aluminum to cut weight and increase fuel economy, according to a study from market analysts Ducker Worldwide cited by The Detroit News. We are already seeing the lightweight metal show up extensively in luxury models from Europe, but with the impending launch of aluminum-intensive 2015 Ford F-150 (pictured above), North America is using it even more, as well. The report predicts 70 percent of US pickups to have aluminum bodies by 2025.
It won't just be pickups that see the benefit, though. The average amount of aluminum in US vehicles is forecasted by the study to grow from an average of 350 pounds in 2013 to about 550 pounds by 2025. The most common parts to use it will be hoods, doors and - to some extent - roofs, as well.
The massive increase in pickups' aluminum content hardly seems surprising. The F-150 is predicted to use so much that it might cause a short-term shortage, according to one earlier report. At the same time General Motors is heavily rumored to be negotiating with suppliers for the next generation Chevrolet Silverado and GMC Sierra. Ram is the last holdout of the Big Three, but the study predicts that not to last.

Ford Focus PHEV on the way?

A refreshed Ford Focus is in the works and that means a few details are leaking out. Spy shots from last month indicated the Focus will have a gaping grille just like its "One Ford" global C-segment comrade, the Fiesta. While Ford is being quiet about it, the Focus could also be getting an "Energi" option, joining the C-Max Energi and Fusion Energi in Ford's plug-in hybrid family. The Focus will likely use technology originated in the C-Max Energi that combines a 2.0-liter gasoline engine with an electric motor capable of a 20-mile range, according to Autoexpress. The pure electric Focus is expected to stay in the lineup despite its slow sales; its price range should be similar to what's on the market now. The third-generation Focus looked good enough to become the top-selling nameplate in the world in 2012. Some exterior changes to look for in the Euro-spec model at the Geneva Motor Show in March include a reshaped hood, front wing endplate and rear bumper. Interior spy shots have hinted at an updated dashboard design and a simplified, less cluttered control panel with updated climate controls. Under the hood, there are quite a few power options rumored to be available - a gasoline EcoBoost with up to 123 horsepower and two turbo-diesel TDCI options, a 1.6-liter or 2.0-liter mills that would produce between 94 hp and 161 hp. Then there are new 1.5-liter diesel and 1.5-liter EcoBoost gasoline variants that meet regulations in China, Brazil and Russia.