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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.

Detroit automakers keep their masks on to keep the factories running

United Auto Workers members leave the Fiat Chrysler Automobiles Warren Truck Plant in May. Fiat Chrysler along with rivals Ford and General Motors Co., restarted the assembly lines after several weeks of coronavirus lockdown. (AP)   DETROIT — When the coronavirus pandemic slammed the United States in March, the Detroit Three automakers shut their plants and brought their North American vehicle production to an unprecedented cold stop. Now, four months after a slow and sometimes bumpy restart in May, many General Motors, Ford and Fiat Chrysler Automobiles  factories are working at close to full speed, chasing a stronger-than-expected recovery in sales. So far, none of the Detroit Three has had a major COVID-19 outbreak since restarting production, even as the coronavirus is surging in Midwestern and Southern communities outside factory walls. "We have people testing positive, but it's not affecting operations," said Ford global manufacturing chief Gary Johnson. Keeping the pandemic at bay has pushed the automakers and 156,000 U.S. factory employees represented by the United Auto Workers into unfamiliar work routines and extraordinary levels of cooperation among the rival automakers that will have to be sustained for months to come. For automakers, the automakers' COVID response has been as much about instilling new habits as relying on new technology. Workers log their symptoms, or lack of them, into smartphone apps and walk past temperature scanners to get to their work stations. But company and union executives said masks, along with physical distancing, are the key to keeping assembly lines rolling. "The mask is the foundation" of protecting workers on the job, said Johnson. Complaints about masks Autoworkers are accustomed to wearing protective gear such as shatterproof glasses and gloves. Masks that cover the mouth and nose, however, were not standard equipment on auto assembly lines, and were a tough sell at first. "The biggest complaint is wearing a mask," United Auto Workers President Rory Gamble told Reuters. "A lot of our members perform physical tasks. Wearing the mask inhibits breathing." Beyond that, Gamble said, masks and distancing make it harder for workers to have conversations on the job or socialize during breaks. "ThatÂ’s pretty much out the window, and it makes for a longer day," he said. Masks make it harder for co-workers to read each other's expressions — often crucial in the noisy environment of a car plant.

Where the 2023 GMC Sierra AT4X fits into the hierarchy of off-road trucks

The world of off-road pickups sure seems like it's getting crowded, but the reality is that half-ton trucks were always pretty capable, even with what seemed like fairly basic 4x4 packages. It wasn't until recently that manufacturers really started to carve out different off-road niches for their mainstream pickup offerings. With the introduction of the 2022 GMC Sierra 1500 AT4X (alongside its mechanical twin, the Chevy Silverado ZR2), the crowd has grown even thicker. Even we have trouble keeping up with the increased segmentation of off-road pickup trucks, so we threw together this handy guide to help you understand just where these various packages fit into the broader pickup hierarchy. Let's dive in.  Your basics If we say "Z71" or "FX4" to you, both will probably ring a bell. That's because they've been around a few days short of forever and their respective customers have grown so used to these package codes that OEMs got into the habit of just plastering them on the side of so-equipped truck beds. Anybody who sells a pickup truck offers some sort of basic off-road prep package like this one. Z71 is found on GM vehicles; FX4 is Ford's. Ram just calls it "Off Road Group," but no matter what you call them, they're all pretty similar.  Typical upgrades for this category include some additional ground clearance, a basic all-terrain tire, heavy-duty suspension upgrades and likely either a limited-slip or locking rear differential. These are pretty handy for anything beyond a rutted dirt road. On newer trucks — especially on higher trim levels — you'll probably also get some dedicated off-road drive modes.  Mid-range This is where things start to get interesting. To qualify for this category, a locking rear differential is a must. Most of the names in this segment are well-established too, though some (Nissan Titan Pro-4X, anyone?) may not necessarily be on your radar. The Toyota Tundra TRD Pro checks in here, as does the Ram Rebel, Chevy Silverado Trail Boss and GMC Sierra AT4 (no X!).  Realistically, if there's somewhere you need to go and one of these trucks won't do it, you might want to consider a helicopter. But it's 2021, and our thirst for capability is strong, so of course, there's a way to spend more of your money on this type of thing. Onward! Entry-hardcore Here we are, the home of the new 2022 GMC Sierra AT4X and Chevrolet Silverado ZR2. This is a tiny niche, otherwise occupied only by the Ford F-150 Tremor.