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2015 Ford F-150 enters production

Ford has given the F-150 a dramatic makeover for 2015, switching to an aluminum body that helps reduce weight by about 700 pounds. Because the truck is dramatically different, Ford also had to change the way it makes the F-150, so we went inside its sprawling factory in Dearborn, MI, this week to see the Blue Oval's new manufacturing techniques in action.
The company has added 850 jobs at the site and upgraded its stamping and tool and die facilities. The body shop is also modernized, and it has been fitted with 500 new robots that join the structures together. The first 2015 F-150 rolled off the line on Tuesday, and the trucks will begin arriving in dealerships in December. Get a closer look at the F-150's unique assembly process in our video.

Again? Ford issues second 2015 Fusion and Lincoln MKZ seat belt recall

In 2016, Ford issued a recall for 603,392 2013-2016 Fusions and 2013-2015 Lincoln MKZs due to potentially faulty seat belts. Apparently, that wasn't the end of it. Ford announced another recall this week for the same issue, this time covering 108,399 2015 Fusions and MKZs.  In both cases, the seat belt anchor pretensioners are the issue. According to Ford, "increased temperatures generated during deployment of the driver or front-passenger seat belt anchor pretensioner could degrade the tensile strength of the cable below the level needed to restrain an occupant." Basically, heat could weaken the seat belts, and in extreme cases, they wouldn't be able to keep up proper safety standards. Ford knows of at least one injury that has occurred due to this issue.   The recall includes 103,374 vehicles in the United States, 4,002 in Canada, and 1,023 in Mexico. Possibly affected Fusions were built at Ford's Flat Rock Assembly Plant between August 1, 2014 and January 30, 2015. The MKZs were built at the Hermosillo Assembly Plant between August 1, 2014 and November 21, 2014.  As a fix, Ford says dealers will add an extra coating to the seat belt pretensioner cable for protection from the heat. If this recall might affect your vehicle, call your local Ford dealership and use recall reference No. 19S25. This news comes after Ford recalled 1.3 million Fusions and MKZs in 2018 due to the possibility that the steering wheels could fall off. Fusions have also been recalled due to the risk of rolling away.

Ford files patent for 11-speed transmission

The automatic transmission seemed limited to three or four gears for decades, and then the automotive world slowly started to see more ratios becoming available. Today, seven-, eight- or nine-speed gearboxes have become rather common. Ford even has an automatic with 10 gears on the way for the future F-150 Raptor. The Blue Oval might not be done yet, though, because the company also now has a patent on an 11-speed box. The filing, which was discovered by AutoGuide, says this idea "produces eleven forward speed ratios and one reverse speed ratio by selective engagement of three shift elements in various combinations," and the company outlines three different ways of making this possible. The advantage of adding one more ratio is that the gearbox should be able to keep the revs in the ideal portion of the engine's torque curve even longer. Obviously, automakers patent ideas constantly, and applying for one is no guarantee that the tech ever arrives on the market. Conversely, these documents provide a tiny glimpse at one of the brand's focuses of development. If you're mechanically minded or just curious, you can read the entire application here for the technical nitty-gritty.