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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.

Ford F-150 EcoBoost in NHTSA probe for acceleration issue

According to Automotive News, the National Highway Traffic Safety Administration is launching a probe into 400,000 Ford F-150 models over possible acceleration problems. According to the article, NHTSA has received 95 reports "alleging incidents of reduced engine power during hard accelerations" on 2011 to 2013 F-150 models equipped with the company's 3.5-liter EcoBoost V6 engine.
Automotive News reports that Ford has issued three technical service bulletins "related to intermittent stumble/misfire on acceleration from highway cruise in humid or damp conditions," according to the government agency's documents. About one third of the 95 reports NHTSA has received cited humid or rainy conditions when these problems allegedly occurred.
These technical service bulletins have allowed dealers to address a "condition related to moisture accumulation in the charge air cooler during extended highway cruising at constant throttle in humid or damp conditions," AN reports, citing NHTSA documents. Furthermore, the TSB outlines details for "reprogramming the powertrain control module with the latest calibration and installing a new CAC and air deflector plate."

Ford Explorer, Expedition next to go aluminum?

Ford made some serious waves when it unveiled the latest F-150. Instead of making its bodywork out of steel, like just about every other truck on the market, Ford went with aluminum. And you can bet the F-150 won't be the last Ford model to go with the lightweight alloy construction, either.
Our compatriots at Edmunds report that Dearborn is considering replacing two of its most popular SUVs with aluminum versions. One candidate is the Expedition, which would make sense considering that the current model (like the two preceding generations and the fullsize Bronco before it) is based on the F-150's underpinnings. Another is the Explorer, which was traditionally based on the Ranger pickup but went with a car-like unibody chassis in its current iteration. If the Explorer does go the way of aluminum, don't expect it to be a part of its very next update, which is likely due too soon for such major changes.
It would stand to reason that, if the Expedition were to go aluminum, so would the next-generation Lincoln Navigator. Ditto the MKT together with the Explorer. But those aren't likely to be the only models in contention for aluminum construction. Like any other automaker, Ford is under pressure to steadily reduce its carbon emissions and improve its fuel economy figures, prompting it to look at a whole range of measures - including more efficient engines, lower rolling-resistance tires, active aerodynamics and lightweight construction. Expect aluminum to play a big part in that equation moving forward.