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NHTSA opens investigation into Ford Explorer PI brakes

This year more than most, it's pleasant when we can string together a few days without word of an automaker or the National Highway Traffic Safety Administration announcing a bunch of new recalls. It's seemingly been a little quiet on this front lately (barring a spider-related Suzuki issue revealed early today), but now we have word of the government safety agency opening a Preliminary Evaluation into the 2013 Ford Explorer Police Interceptor, a probe that could potentially affect an estimated 20,000 vehicles.
The issue being investigated concerns failures of the front brake hose on the vehicle that show "small splits in the hoses near the body side ferrule of the hose assembly," according to the agency, and the issue could result in longer stopping distances. The feds have reports of 13 malfunctions affecting 11 Explorer units. However, it's important to note that all of the incidents come from a single, unnamed metropolitan police fleet that operates 46 of them. According to The Detroit News, the failures generally took place between December and July.
NHTSA is investigating further to find if this is a more widespread issue than just this one fleet. Ford spokesperson Kelli Felker confirmed to us, "We are cooperating with NHTSA on this investigation, as we always do." Scroll down to read the agency's report.

Ford Fusion and Fusion Hybrid nab five-star ratings from NHTSA

Ford's Fusion and Fusion Hybrid have both received the highest five-star overall safety rating from the National Highway Traffic Safety Administration. The rating is a big upgrade for the Fusion, which was completely redesigned for 2013. The previous model fell one star short of the top rating, after scoring only three stars in the frontal crash test and four stars in the side crash test and rollover evaluations. The 2013 Fusion received four stars in side crash and rollover testing and a full five stars in the front crash test.
Test results for the 2013 Fusion and Fusion Hybrid were greatly improved at least in part due to Ford's Personal Safety System. The system utilizes smarter sensors to gather crash data and tailor the car's restraint systems to the occupants. Seatbelt usage and seat position are taken into account to ensure airbags deploy with less pressure for smaller drivers, more for larger drivers.
The 2013 Fusion twins also received the Insurance Institute for Highway Safety Top Safety Pick+ designation. Read the official press release below.

Ford, Alcoa announce next generation of aluminum lightweighting for F-150

Ford likes what it has seen with the use of aluminum in its world-beating F-150 pickup trucks. Now, the Blue Oval is working with Alcoa to use that company's Micromill material to increase the amount of aluminum in Ford vehicles. In fact, Ford will start using Micromill on 2016 model-year F-150s later this year, and will double the material's use in 2017. The purpose, as you might suspect, is light weighting, which allows Ford to boost towing capacity while adding as little weight as possible. Ford will be the first automaker to use Micromill, and will use it in both structural components and exterior panels. Micromill's rolling-mill system cuts the time it takes to turn molten metal into coil to 20 minutes from about 20 days. Already, Ford has had positive results by using aluminum on its leading pickup truck model. In April, it was announced that the 2015 Ford F-150 achieved a five-star Overall Vehicle Score in the National Highway Traffic Safety Administration's testing. Safety features like inflatable seat belts, adaptive steering columns and a forward collision warning system helped matters. General Motors may have taken note of those results, even after running an ad campaign touting its continued use of steel over aluminum. Last month, GM said it would sink $877 million into its Flint, MI, truck factory. Reuters said much of the expense was to convert many of the bodies for models like the Chevrolet Silverado and GMC Sierra pickups into aluminum. You can take a look at Ford's press release below. Ford Motor Company and Alcoa Inc. are collaborating to produce next-generation automotive aluminum alloys that are more formable and design-friendly. Ford will use Alcoa's Micromill® material in multiple components on the 2016 F-150 – becoming the first automaker to use the advanced automotive aluminum commercially. The companies entered into a joint development agreement to collaborate on next-generation aluminum alloys for automotive parts using Micromill™ technology. ''Light-weighting enables us to design vehicles with great customer attributes – like the F-150, which can tow more, haul more, accelerate quicker and stop faster than the previous F-150, and is more fuel-efficient than ever," said Raj Nair, Ford group vice president and chief technical officer, Global Product Development.