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NHTSA investigating 500k Ford and Mercury cars for lighting failures

The Ford Crown Victoria and Mercury Grand Marquis might be long gone as new models in showrooms, but the National Highway Traffic Safety Administration might check them out yet again for a potential problem. At the urging of North Carolina Consumers Council, the agency may open another investigation into the front lighting control module on vehicles from the 2003-2005 model years, and NHTSA estimates the issue could affect 517,945 vehicles. If the module stops working, it can cause a complete failure of all forward lighting, including the headlights. NHTSA previously investigated the issue in 2008 and 2009 but found no need for a recall, according to Bloomberg. Ford also extended the warranty on the part to 15 years or 250,000 miles. To prompt this new request, the North Carolina Consumers Council received a letter from a woman experiencing the module's failure. Upon further investigation, the council found 604 complaints of this problem on NHTSA's website, including seven crashes. Furthermore, the group has alleged that dealers told customers that the parts to perform the replacement weren't available, despite the extended warranty. According to the government agency, "A defect petition has been opened to evaluate the issue and make a grant or deny decision." Ford spokesperson Kelli Felker tells Autoblog via email, "We will cooperate with NHTSA, as we always do." You can read the council's complete letter to the Feds in PDF format, here. INVESTIGATION Subject : Loss of headlamp/exterior lighting Date Investigation Opened: APR 01, 2015 Date Investigation Closed: Open NHTSA Action Number: DP15002 Component(s): EXTERIOR LIGHTING All Products Associated with this Investigation Vehicle Make Model Model Year(s) FORD CROWN VICTORIA 2003-2005 MERCURY GRAND MARQUIS 2003-2005 Details Manufacturer: Ford Motor Company SUMMARY: The Office of Defects Investigation (ODI) has received a petition from the North Carolina Consumers Council, Inc. requesting a defect investigation of an alleged defect condition resulting in headlight and/or exterior lighting failure on 2003-2005 Ford Crown Victoria and Mercury Grand Marquis vehicles. The petition letter is attached for review. The petitioner alleges a defect in the lighting control module that powers the headlights which can result in the loss of vehicle headlights and/or all exterior lighting while driving. ODI has previously investigated this issue under PE08-066 which was closed without a defect finding.

Automakers' rush on aluminum may result in shortage

Aluminum is the new buzzword in the automotive industry. The latest Range Rover and Range Rover Sport both take advantage of the lightweight material to shave huge amounts of body fat (only it's called "aluminium" over there). Audi and Jaguar have been using the stuff for years in their A8 and XJ, respectively, and now, aluminum is going mainstream, arriving on the 2015 Ford F-150.
While we're excited to see aluminum make an impact outside the premium market, its widespread adoption apparently won't come without some problems, notably in terms of supply. "There isn't an automotive manufacturer that makes vehicles in North America that we're not talking to," Tom Boney, of Novelis, the largest global supplier of aluminum sheetmetal, told The Detroit News.
According to Boney, Ford's use of aluminum on such a large scale has forced auto manufacturers in "every boardroom" to reconsider their plans following the F-150's unveiling, for one simple reason: there's not exactly enough aluminum to go around, at least in the short term. The auto industry presently only accounts for six percent of the aluminum sheet produced, but as the material is adopted by more and more brands, that figure is expected to swell to 25 percent within the next six years.

Autoline streaming live from Detroit Auto Show right now

As you can already see, the Autoblog team is digging deep to bring you everything from the Detroit Auto Show media days today and tomorrow, with obsessive coverage of all of the new sheetmetal, hot concepts and industry news. But we're hardly alone in Cobo Hall, and our friend John McElroy and his Autoline team have fired up a live video webcast with interviews from the show floor that you can watch right now by scrolling below. The daily streaming broadcasts start at 1:00 PM Eastern today and tomorrow, with a large number of A-list executives, designers, and product planners from both domestic and foreign automakers are expected to sit in. Interviewees scheduled to appear include Al Gardner, President and CEO of Chrysler; David Zuchowski, brand-new President and CEO of Hyundai Motor America; Doug Scott, Truck Group Marketing Manager at Ford; and Peter Schreyer, President and Chief Design Officer at Kia. For the live feed and a full list of guests for both days, scroll below. Live broadcast by Ustream [Pop-out Chat Window] Day One Al Gardner, President and CEO, Chrysler Brand Ludwig Willisch, President and CEO, BMW of North America Doug Scott, Truck Group Marketing Manager, Ford Tim Mahoney, Chief Marketing Officer, Global Chevrolet Heiko Schmidt, Head of C-Class Product Planning, Mercedes-Benz USA Filip Brabec, Product Planning Manager, Audi of America Day Two Bob Ferguson, Senior Vice President, Global Cadillac Dave Zuchowski, President and CEO, Hyundai Motor America Mike Manley, President & CEO, Jeep Brand Peter Schreyer, President and Chief Design Officer, Kia Tom Kearns, Chief Designer, Kia Design Center America Jim Lentz, COO, Toyota Motor NA Tony Nicolosi, President & CEO, Volvo Cars North America Jose Munoz, Executive VP & Chairman, Nissan Americas Auto News Detroit Auto Show Audi BMW Chrysler Ford Kia Videos Detroit Autoblog 2014 Detroit Auto Show autoline Peter Schreyer