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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.

2020 Ford Police Interceptor Utility dominates Michigan State Police testing

The Michigan State Police has released its preliminary findings from testing the 2019 crop of police vehicles, and the results are a bit surprising. The consistent top performer of the bunch was the 2020 Ford Police Interceptor Utility, better known to civilians as the Ford Explorer. Specifically, the top performer was the model with the new turbocharged 3.0-liter V6. The Michigan State Police conducts acceleration, top speed, braking and lap time tests of all the available police vehicles. The 3.0-liter Police Interceptor Utility was the fastest to 60 mph at 5.77 seconds, had the highest top speed of 150 mph, and the best average lap time of 1:36.47. The lap time was particularly impressive as it was just over half a second faster than the next quickest car, the all-wheel-drive V8 Charger. View 13 Photos Still, the 2019 Dodge Charger gave the Explorer a serious run for its money. The all-wheel-drive V8 Charger was only 0.1 seconds behind the Explorer to 60 mph with a time of 5.87 seconds, and the rear-drive version was third quickest at 6.15 seconds. Both V8 Chargers were only 1 mph off of the Explorer's top speed, and the V6 example was third fastest at 141 mph. We already mentioned the all-wheel-drive V8 Charger was half a second off the Explorer's lap time, and the rear-drive variant was just over 1 second behind, giving it the third fastest average time. Dodge also took home braking bragging rights. The V6 Charger won out with a distance of 126.9 feet, followed by the rear-drive V8 Charger with 128 feet, and the V6 Durango Pursuit stopping at 128.8 feet. Now of course where there are winners, there are also losers. The slowest accelerating police car was the Ford Police Responder Hybrid Sedan, better known as the Fusion Hybrid, with a time of 9.24 seconds. At 8.59 seconds was the V6 Dodge Durango, and the V8 Chevy Tahoe with four-wheel-drive was third slowest at 7.98 seconds. Lowest top speed was 106 mph with the Ford F-150 Police Responder with the 3.5-liter turbocharged V6, followed by the V6 and V8 Durangos with 117- and 118-mph top speeds respectively. In braking, the Chevy Tahoes performed the worst with the rear-drive version stopping at 145.7 feet and the four-wheel-drive version stopping at 142.5 feet. The F-150 followed with 141.9 feet. When it came to lap times, the Fusion Hybrid lapped the slowest with a time of 1:46.31. The V6 Durango was about a second faster with a time of 1:45.45.

Ford expands door-latch recall to 156k more vehicles, nearly 550k total

Ford is being inundated with recalls as of late. Just days ago it called in over 590,000 cars for a variety of issues. Now, the Blue Oval has announced an expansion of its door latch campaign to cover an additional 156,000 vehicles in North America. Counting the original 389,585 cars, this has brought the total to 545,906. Under this expansion, the same models are affected, but Ford is broadening the coverage dates in some cases. The recall covers the 2011-2014 Fiesta, 2013-2014 Fusion, and 2013-2014 Lincoln MKZ; there are 456,440 units in the US, 50,681 in Canada, and 38,785 in Mexico in need of repair. In these vehicles, a door might not latch because of a broken pawl spring tab. Even if a passenger can successfully close it, the faulty part could unlatch while driving. According to Ford, there are two allegations of doors bounding back and hitting a person. There's also one possible accident from a door opening and striking another vehicle. Dealers will replace all of the latches to fix the problem. Related Video: MAY 1, 2015 | DEARBORN, MICH. FORD EXPANDS DOOR LATCH SAFETY RECALL IN NORTH AMERICA DEARBORN, Mich., May 1, 2015 – Ford Motor Company is expanding a safety recall regarding door latches to include approximately 156,000 more vehicles at the request of the National Highway Traffic Safety Administration, bringing the total to 545,906 vehicles in North America. The door latch in certain vehicles may experience a broken pawl spring tab, which typically results in a condition where the door will not latch. If a customer is then able to latch the door, there is a potential the door may unlatch while driving, increasing the risk of injury. Ford is aware of a total two allegations of soreness resulting from an unlatched door bouncing back when the customer attempted to close it, and one accident allegation when an unlatched door swung open and struck the adjacent vehicle as the driver was pulling into a parking space. Affected vehicles include certain 2011-14 Fiesta vehicles built at Cuautitlan Assembly Plant, Nov. 3, 2009 to May 31, 2013; certain 2013-14 Fusion vehicles built at Hermosillo Assembly Plant, Feb. 1, 2012 to May 31, 2013; certain 2014 Fusion vehicles built at Flat Rock Assembly Plant, April 12, 2013 to April 26, 2013; and certain 2013-14 Lincoln MKZ vehicles built at Hermosillo Assembly Plant, Feb. 1, 2012 to May 31, 2013. There are 456,440 vehicles in the United States and federalized territories, 50,681 in Canada and 38,785 in Mexico.