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Experts wonder if aluminum F-150 gives Ford a real advantage

There's no doubt that Ford is taking a risk in producing the body of its upcoming new F-150 pickup truck in aluminum. What is up for debate, however, is whether aluminum was a wise risk to take in the first place. Wards Auto took the opportunity to poll some experts on the subject of aluminum versus steel in the automotive sector, with somewhat unsurprising results.
Richard Schultz, a project consultant at Ducker Worldwide, which bills itself as "a leading aluminum industry consultant (though they also deal in steels), suggests that the potential drawbacks to aluminum - higher costs, lower supply - aren't really impediments to the auto industry's increased acceptance of the lightweight metal.
Similarly, Randall Scheps, global automotive marketing director for Alcoa, a massive aluminum producer, counters claims that aluminum is less safe for vehicle occupants, suggesting that the use of aluminum can actually increase safety as it could potentially allow for larger vehicles with more crush space than steel.

Ford recalls select Explorer, E-Series vans

Just a few days ago we brought you news that Ford had issued a recall on 28,000 units of the Edge crossover for problems related to the fuel line. But now the Blue Oval has issued recall notices on two more of its larger vehicles.
The first relates to the Explorer, 395 examples of which from the 2011 and 2012 model years were found to have problems with their steering systems if they underwent service after September 1, 2013. An apparent software glitch could lock the steering gear, preventing the driver from steering the vehicle and thereby increasing the risk of a crash. As a result, Ford dealers are being instructed to check their records to identify the problematic vehicles and bring them in to have the steering gear replaced. Details of the recall can be found in the PDF linked here.
The second problem revolves around E-Series vans that may develop bubbles in their windshields under hot temperatures. The decrease in visibility through the problematic windshield could - you guessed it - "increase the risk of a crash." As a result, Ford is calling in 4,532 units of the E-150, E-250, E-350 and E-450 vans built in the relatively short window between May 12 and May 26, 2011. Details of this recall can be found in the notice below from the National Highway Traffic Safety Administration.

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.