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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.

Ford issues six recalls covering 101,000 vehicles for multiple issues

Ford is announcing six separate recalls for a variety of issues affecting a dozen models and a total of 100,610 vehicles in North America. However, according to Ford spokesperson Kelli Felker, "None of them have caused accidents or injuries." Half of them cover fewer than 1,000 cars.
The largest recall covers 92,022 North American examples (about 83,250 in the US) of some models of the Ford Taurus, Lincoln MKS, Ford Interceptor, Flex and Lincoln MKT from the 2013 and 2014 model years; the 2012-2014 Edge and the 2014 Lincoln MKX. All of them have a potential issue with the halfshaft on the right side that might not be fully seated and could move outward over time. If it shifts too far, the models may no longer be able to drive, and the condition could also allow the vehicles to roll away, even when in Park. Dealers will inspect the shaft to make sure it's seated and will replace the part if necessary.
The next-largest recall covers 5,264 North American examples (4,867 in the US) of the Ford F59 Commercial Stripped Chassis from the 2011-2014 model years. It's possible that an electrical junction box can corrode in areas with salty roads and short circuit. The problem could potentially cause a fire. Dealers will replace the box with an improved design.

2015 Ford F-150 enters production

Ford has given the F-150 a dramatic makeover for 2015, switching to an aluminum body that helps reduce weight by about 700 pounds. Because the truck is dramatically different, Ford also had to change the way it makes the F-150, so we went inside its sprawling factory in Dearborn, MI, this week to see the Blue Oval's new manufacturing techniques in action.
The company has added 850 jobs at the site and upgraded its stamping and tool and die facilities. The body shop is also modernized, and it has been fitted with 500 new robots that join the structures together. The first 2015 F-150 rolled off the line on Tuesday, and the trucks will begin arriving in dealerships in December. Get a closer look at the F-150's unique assembly process in our video.