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Feds open investigation into Chevy Express, Ford Freestar rust issues

'Tis the season... for road salt. And with that, comes rust. And what does rust bring? Well, for Ford and General Motors, a National Highway Traffic Safety Administration investigation. According to The Detroit News, NHTSA is looking into potential recalls issues with Chevrolet Express vans and Ford Freestar minivans.
The feds have received five complaints that rust has caused leaking fuel filler pipes on 2003 Express vans. Separately, seven complaints have been filed over excessive rust in the rear wheel wells of 2004 Ford Freestar and Mercury Monterey minivans. The Freestar and Monterey went out of production in 2007. Neither issue has resulted in any crashes or injuries, according to the report.

Ford Mustang GT500 successor spied near SVT

Details about the next-gen Ford Mustang are scarce, and there's even less information out there about the upcoming replacement for the Shelby GT500. Previously rumored to drop the Shelby name and wear the GT350 moniker, the highest-performance Mustang has just been spotted testing near Ford's SVT operations.
Despite being cloaked in heavy camouflage, we can instantly tell this prototype is different from other Mustang spy shots we've seen in the past. Aside from the Shelby-spec wheels, quad exhaust outlets (previous spy shots show only two) and beefier brakes, this car also has air intakes on the hood and front fenders. These elements help to neither prove nor dismiss rumors that the next SVT Mustang will be naturally aspirated. It also looks like Ford is may be planning some changes to this car's rear suspension, as there is some extra camouflage added beneath the rear end of this prototype.
As a bonus, these spy shots also give us our first look inside the new Mustang, revealing a new steering wheel (with more buttons) and a glimpse of the dual-pod instrument gauges. Check out past spy shots of the 2015 Mustang showing off its new face and driving around town.

Recharge Wrap-up: Ford 1.0L EcoBoost a hit in Europe; Build a tiny inverter, win $1 million

In Europe, Ford's 1.0-liter EcoBoost engine is the best-selling turbocharged gasoline engine. The three-cylinder motor powers 20 percent of new Fords sold in Europe. Earlier this year, it won its third International Engine of the Year award, and between January and June, it was sold in about 120,000 cars. So far this year, 38 percent of Fords sold in the Netherlands, 35 percent in Denmark and 32 percent in Switzerland have been powered by the 1.0-liter EcoBoost. The engine's turbocharger spins at 248,000 rpm, and provides 24 psi of pressure. The engine produces up to 138 horsepower, depending on the version. Read more in the press release below. When lithium-ion battery packs are retired from the road, remanufacturing, repurposing, and recycling are worthwhile options, according to a study by Mineta Transportation Institute. The study included a cost-benefit analysis of those three options, and found remanufacturing to be the best route. To get the most out of them, batteries should be tested and have their damaged cells replaced then put back to use. Repurposing is the second best option, using the remaining available charge for something besides cars. Recycling on its own isn't profitable, but it could make economic sense with "increased technological breakthroughs." Learn more at Recycling International or download the report here. A smaller inverter for EVs can win you $1 million. The Little Box Challenge is an open competition to build a power inverter with a density of at least 50 watts per cubic inch. Google and the Institute of Electrical and Electronics Engineers (IEEE) are offering the hefty prize to the team that builds the inverter with the highest power density within an enclosed volume of 40 cubic inches. Teams must register by September 30. Read more at Green Car Congress or learn more at the Little Box Challenge website.