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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.

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.

2019 Chevy Silverado 1500 vs. 2019 Ram 1500 vs. 2018 Ford F-150: How they compare

The full-size pickup truck market is seriously hot right now. Both Ram and Chevrolet have introduced completely redesigned trucks, the 2019 Ram 1500 and the 2019 Chevy Silverado, and as the companies slowly roll each one out, more and more information comes to light. We've put together this comparison post to help you keep track of all the features and specifications of each of these new models, along with the updated 2018 Ford F-150. Among the stats we'll take a look at are engines, power, fuel economy, trim levels, weight and more. Weight savings Both the 2019 Ram 1500 and 2019 Chevy Silverado 1500 have gone on a diet for the new model year, similar to the one the F-150 went on in 2015. The Silverado is the weight-loss leader, having shed 450 pounds when comparing quad-cab V8 models. The Ram 1500 lost 225 pounds compared to the current truck. Both trucks achieve their weight loss in part due to the use of aluminum parts. On the Silverado, the hood, doors, and tailgate are aluminum, while on the Ram, just the hood and tailgate are aluminum on the body. Compare that to the F-150, which uses aluminum for all exterior body panels for a total weight loss of up to 732 pounds, which makes the aluminum-intensive F-150 the weight-loss leader. View 160 Photos Engines and transmissions There's only a bit of overlap in powertrains on the Ram 1500 and Chevy Silverado. Each has a V8 for the top engine. The Ram's is a 5.7-liter Hemi V8 making 395 horsepower and 410 pound-feet of torque. The Silverado will once again use a 6.2-liter V8 as its range topper with the same 420 horsepower and 460 pound-feet of torque as the current model. Both of these V8s boast some extra fuel saving technology. The Chevy's 6.2-liter (and some 5.3-liters) comes with the company's latest cylinder deactivation system that can shut off any or nearly all of the eight cylinders. The Ram's V8 boasts an optional 48-volt mild-hybrid system that, in addition to likely helping fuel economy, can provide up to 130 pound-feet of torque right off the line. With the Ram, fuel economy sees an improvement of 2 mpg in the city and combined ratings for 17 and 19 respectively. Highway fuel economy improves by 1 mpg to 23 with two-wheel drive and 22 with four-wheel drive. The Silverado's 6.2-liter V8 only improves city fuel economy by 1 mpg to 16, and actually loses 1 mpg on the highway. The new 5.3-liter engine with the fancy cylinder deactivation does see an improvement over the simpler version.