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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.

Swedish car mag says Ford Mondeo is dangerously, illegally overweight [w/video]

Sweden's Teknikens Varld has a reputation for being very persnickety when it comes to auto safety testing, and its latest catch is the Mondeo Titanium Estate 2.0 TDCi 150 bhp S6 MPS (basically a station wagon variant of the Fusion). In addition to the model's mile-long name, it has another problem according to the Swedes, because its weight on the scales does not equal the official numbers for the vehicle. Teknikens Varld claims the wagon is dangerously overweight because it weighs in 4,145 pounds, while Ford officially lists its weight at 3,530 pounds. That 615-pound disparity means that if a family loads it to what they think is the model's gross vehicle weight, it will actually be too heavy, and therefore illegal to drive in Sweden. According to the magazine, when it tried doing this, the rear wheels scraped against the wells, and the estate failed the mag's legendary moose test. However, at 220 pounds over the limit, it passed the test. When reached for comment by Autoblog, Jay Ward, Senior Manager at Ford of Europe Product Communications, explained the reason for the deviation between the official numbers and the magazine's test: "We are aware of this, but this is not an issue that relates specifically to the safety of the Mondeo, but is in fact related to the way in which the cars are tested by the authorities. We provided an Ambiente model for the testing but the car that featured in the magazine test was a Titanium model which has a different weight. We are in discussion with the Swedish Transport Agency to change the framework so the real weight of the Titanium model is reported instead of the Ambiente model which will resolve the issue." Teknikens Varld is well-known for calling out automakers for perceived transgressions. Most recently it leveled criticisms against the all-wheel drive system in the Honda CR-V, and both the Jeep Grand Cherokee and Porsche Macan failed its moose test. Scroll down for the magazine's video of weighing the Mondeo Estate and the model's test results. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. The new Ford Mondeo is dangerously overweight The new Ford Mondeo is a great car, which Teknikens Varld's test shows, but there is one problem – the weight. Mondeo weighs 279 kg more than Ford claims. With big load (ie family plus luggage) the car therefore becomes illegal to drive.

Ford, Chrysler and Mazda expand scope of Takata airbag recalls

The scope of the Takata airbag inflator recall is ballooning once again across the United States. Where Honda has elected to take its driver-side airbag campaign nationwide, Chrysler Group and Ford have now announced expanded regional actions to cover some passenger-side airbag inflators. Mazda is adding more regions, as well. For Chrysler Group, the campaign covers the inflators on 149,150 examples of the 2003-model-year Ram 1500, 2500 and 3500 pickups. The recall is limited to vehicles sold or ever registered in Alabama, Florida, Georgia, Hawaii, Louisiana, Mississippi, Texas and the territories of American Samoa, Guam, Puerto Rico, Saipan, and the Virgin Islands. The company will begin notifying affected customers on January 19. According to Chrysler's announcement of the action, the passenger side inflators in these trucks "are of a type that is not used in any of the other vehicles affected by Chrysler Group's regional field action." The automaker says that it's not aware of any actual failures or accidents in these pickups and even claims there are no "observed failures in laboratory testing of its airbag modules." The company is continuing to study the problem, though. Ford is taking a similar step by issuing a recall of inflators for 38,500 examples of the 2004-2005 Ranger and 2005-2006 Ford GT. The campaign only affects vehicles originally sold or ever registered in Florida, Hawaii, Puerto Rico and the US Virgin Islands. Certain zip codes of Georgia, Alabama, Mississippi, Louisiana, Texas, Guam, Saipan and American Samoa are also covered. There's already precedent for passenger-side airbags to be covered under the Takata inflator recall. When many automakers announced campaigns in June, BMW, Chrysler, Ford, Honda, Mazda, Nissan and Toyota all included that side in some of their repairs. Subaru subsequently did, as well. In addition, Mazda is expanding the scope of its recall to add Florida, Puerto Rico, Hawaii, Saipan, Guam, American Samoa, US Virgin Islands, Georgia, Alabama, Louisiana, Mississippi and Texas to the affected areas. The company estimates that it has a total of 86,773 vehicles in need of repair. Mazda is also teaming with Toyota to begin independent testing of the Takata inflators. Scroll down to read all of the automakers' announcements of these newly expanded recalls. Statement: Air-Bag Inflators December 3, 2014 , Auburn Hills, Mich.