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How Ford secretly used customers to test its aluminum F-150 [w/video]

Automakers getting clever about disguising development vehicles isn't anything new. Between mules wearing the sheetmetal of other cars and prototypes decked out in as much camouflage as is practical, automakers know how to make it very difficult for the general public to get an exact idea of what kind of vehicle is in development. Ford, though, is rapidly becoming the master.
We knew that the Blue Oval originally tested the durability of the aluminum construction being used for the 2015 F-150 by building an all-aluminum 2014 truck and entering it in the Baja 1000 off-road race. That's no longer a secret. What we didn't know, though, is that the aluminum development dates back to before even that, and that some of the people in question had no idea what it was they were working with.
Ford says this is the first time prototypes have ever been handed over to the public.

2015 F-150 launch to curb Ford profits?

Ford is making a big bet on aluminum with its new 2015 F-150, and it's possible that the decision will hurt the company financially, at least in the short term. After earning a record $8.6 billion in 2013, the Blue Oval does not expect to set another record in 2014. According to Automotive News, that's "largely attributable to F Series," says Bob Shanks, Ford's Chief Financial Officer.
To retool for the new F-150, Ford will idle its Dearborn Truck Plant in Michigan for 11 weeks and the Ford Kansas City Assembly Plant in Missouri for 2 weeks. "3 of the 13 overall weeks occur during what normally is our summer shutdown timeframe," said Mike Levine, Ford Trucks Communication Manager, in an email to Autoblog. The extra 10 weeks will be preparing for the more aluminum-intensive construction for the trucks and will mean over 2 months of no F-150s being made. For comparison's sake, Chrysler boss Sergio Marchionne just confirmed that the 200 plant in Sterling Heights, MI will be down for 30 days to retool for the new model, but obviously there are many more F-150 production variables than for the midsize sedan.
Levine notes that Ford is already running three shifts at both plants, and says the automaker has plans to ensure that there is adequate supply of the full-size pickups during the retooling process. The company does not want to suffer a shortage of the vehicle that accounted for 31-percent of its 2013 US sales and an even bigger percentage of its profits.

Ford recalls EcoBoost-powered F-150 and SUVs for brake fluid leak

Ford is recalling approximately 280,000 trucks and SUVs equipped with its 3.5-liter EcoBoost engine to address a potential brake fluid leak. The recall covers the 2016-2017 Ford F-150, 2016-2017 Ford Expedition and the 2016-2017 Lincoln Navigator.  According to Ford's defect report, the issue stems from contamination in the brake fluid causing degradation or damage to the seals in the brake master cylinder, allowing fluid to escape. Ford says that braking performance is not immediately impacted by the leak, and owners may not realize there's a problem until a brake malfunction indicator appears in the cluster, accompanied by a chime.  "If the brake fluid in the reservoir is depleted to a predetermined level, the driver will receive an audible chime, message center alert, and red brake warning indicator in the instrument cluster," Ford said in its defect report to NHTSA. "If the driver continues to operate the vehicle, the drive may begin to experience a change in brake pedal travel and feel, and increased pedal effort." "If a loss of brake fluid is substantial enough to reduce brake function to the front wheels, full braking function would remain in the rear wheel circuit. However, reduced brake function in the front wheels can extend stopping distance, increasing the risk of a crash," Ford said.  The issue can be addressed with a replacement brake master cylinder, which Ford will install free of charge. Ford has already begun notifying dealers and will send notices to customers starting in April.  Recalls Ford Lincoln Ownership Safety Truck SUV