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Ford F-150 production hampered by frame shortage

If anyone has questions about how Ford's new aluminum-bodied F-150 will hold up, it's not buyers. Orders are so strong for the fullsize pickup that competitors General Motors and Ram are discounting their offerings to hold onto market share. It's a shame for the Blue Oval then, that it can't build all the trucks it needs because frame supplier Metalsa isn't delivering enough frames. Neither Ford nor Metalsa has said what the problem is, but Ford employees are at Metalsa's Kentucky plant trying to get it sorted out, Automotive News reports. Overtime shifts at the Dearborn Truck Plant and the Kansas City Assembly Plant have been canceled due to the shortage that's been a problem for at least two months now. The issue is exacerbated by this being the changeover period in production from the old model to the new, which comes with its own issues. That would help explain why even though Dearborn production finished ramping up in January, output in April was down 9.2 percent compared to last year, according to AN. Transaction prices are up for the new truck, but overall F-150 production in Q1 was down 40 percent, and missing product means missing profits. Combined with the production drop for the new Ford Edge, the company's Q1 bottom line was robbed of $1 billion. It isn't clear when the frame issue will be solved, but workers at the plants are ready to run "all-out" when it is. Related Video: News Source: Automotive News - sub. req.Image Credit: Copyright 2015 Drew Phillips / AOL Plants/Manufacturing Ford Truck kansas city assembly plant

IIHS updates overlap test: 2 SUVs get good marks, 9 fare poorly

Vehicles in crashes keep occupants safe by deforming around the cabin in a way that maintains cabin integrity. The Insurance Institute for Highway Safety's moderate overlap test, introduced in 1995, has been a huge contributor to improved safety for front-row passengers in a crash. IIHS President David Harkey said, "Thanks to automakers’ improvements, drivers in most vehicles are nearly 50% less likely to be killed in a frontal crash today than they were 25 years ago." In the 'unintentional side effects' column, crash safety has gotten worse for passengers in the back seats. When carmakers reengineered the front crash structure to protect the driver, more crash forces got distributed throughout the rear. IIHS research claims rear passengers have a 46% greater risk of fatal injury than front-row passengers, but back-seaters haven't benefited from the same upgrades in safety as the front row. The IIHS updated its moderate overlap test to address the issue, putting 15 vehicles through the new regime. Two earned good ratings — the 2023 Ford Escape and the 2021-2023 Volvo XC40 — one was acceptable, three were marginal and nine were rated poor. Every one of the crossovers sampled got good marks for all passengers in the original test. That test sees 40% of vehicle's width on the driver's side impacting an aluminum honeycomb barrier at 40 miles per hour. The updated test puts a crash dummy representing small woman or 12-year-old child in the seat behind the driver, the dummy's sensors and grease paint measuring the effectiveness of the restraints and the forces a human body would need to endure. To achieve a good rating, the "measurements must not exceed limits indicating excessive risk of injury to the head, neck, chest, abdomen or thigh." An institute engineer said, "In real-world crashes, chest injuries are the most common serious rear-seat injuries for adults." The sensors and video evidence showed back seat dummies in the Escape and XC40 endured minimal risk of injuries from excessive crash forces, from submarining under the seat belt, or from unwanted interaction with the side curtain airbag.   The Toyota RAV4 scored acceptable. The second-row dummy also endured minimal risk of injury to the chest and lower extremities. However, the lap belt slipped upward in a way that could increase abdominal injuries, and after the dummy's head dipped during crash impact, the head came back up between the rear curtain airbag and rear window.

We test the 2016 Ford F-150 Pro Trailer Backup Assist

There are some automotive tasks that are more or less impossible the first time you attempt them, no matter your skill level. Remember the first time you had to back a trailer into position? Yeah, you'd have more luck disarming a nuclear bomb than getting the trailer where you're aiming. Ford is preparing to debut a technology that takes the mystery out of reversing a trailer, with the new Pro Trailer Backup Assist. Available on the entire 2016 F-150 range, the system essentially allows owners to drive their trailers by way of a dash-mounted knob. Turn the knob and the steering wheel automagically turns to the correct angle, leading the trailer in the desired direction. The steering wheel twirls about as needed, although drivers still have direct control of the accelerator and brake pedals, much as they do with Ford's Enhanced Active Park Assist system. Ford has spent eight years developing the system, the company's engineers told us. Drivers will need to measure their trailers a certain way and fit the checked reference sticker you can see in the gallery, although once a measurement is stored in the system, it can easily be recalled using the display in the instrument cluster. The system can stow the measurements for 10 trailers, and can accommodate tow-behinds up to 33 feet long. As of right now, though, the PTBA can't work with gooseneck trailers or fifth-wheels, although we're betting Ford is hard at work to accommodate those more substantial setups. "Pro Trailer Backup Assist is a smart solution to save time and increase productivity for our customers," Doug Scott, Ford Truck's marketing manager, said in the attached statement. "Instead of struggling to back up their trailer, they can spend more time on the job or enjoying the lake." We took part in a hands-on demo of the new system off the Detroit River, near Grosse Ile, MI. Full disclosure, we didn't back the trailer into the water, (your author had no interest in potentially damaging the roughly $50,000 boat/trailer Ford brought in for the test). We did, however, conduct a brief test in the safe confines of a nearby parking lot. Our immediate impression of this technology is that it will be a boon to novices or first-time towers, a group of which your author is a member. It takes the mystery out of backing up a trailer, and while there's still a learning curve involved, it's significantly easier than doing things the old-fashioned way.