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2020 Ford Explorer, Lincoln Aviator reportedly facing numerous QC issues

A lengthy report in the Detroit Free Press delves into a range of quality control issues confronting the 2020 Ford Explorer and its luxury platform sibling, the 2020 Lincoln Aviator. Freep says it's been following the issue for two months, tapping various unnamed sources for information on the automaker's unorthodox route to resolution. Seems the problem is Explorers and Aviators leaving the production line at the Chicago Assembly Plant with flaws in areas like the chassis, transmission and suspension, said vehicles trucked to Ford's Flat Rock Assembly Plant (FRAP) outside of Detroit for repair. The estimates range from 10,000 to 18,000 vehicles affected, numbers so high that Ford has sought help from Roush Engineering in nearby Allen Park, and brought workers and managers from other plants in the Midwest to FRAP to get vehicles repaired and shipped to dealers. Ford hasn't shared the nature of the problems with anyone outside the company, including dealers and customers. Freep's sources are said to include workers who have provided photos of certain vehicles and of tents used to house parts at the FRAP repair site. The Explorer chassis allegedly has an unidentified problem that engineers are using X-rays to diagnose, and the transmission is having problems sensing when it's in park or going into park. Both the Explorer and Aviator have come off the line with HVAC units that only blow hot air. And the Aviator's height-adjustable suspension enters failure mode for unknown reasons. These come on top of quotidian mishaps common to every new vehicle, but that are meant to be sorted in pre-production, like missing emblems and trim pieces. They also come on top of a recall in early August issued for the Explorer and Aviator concerning the instrument cluster and parking brake, and another at the end of August over rear seatbacks that could collapse in a crash. An automaker spokesperson told Freep, "Making updates to preproduction models based on all-new platforms as they roll off the assembly line – is standard industry practice." Except these aren't pre-production, these are early production vehicles that paying customers and dealers are waiting for, and some of the affected vehicles have been pulled off dealer lots. Dealers say they are fine waiting for the trucks to get sorted out, and they'd rather have Ford fix the problems before the SUVs go to customers.

Lincoln Continental brings back suicide doors with Coach Door Edition

Remember that teaser image from last week indicating the Lincoln Continental would get suicide doors? Well, it's happening, and we got to check out a prototype late last week. As you can see from the photos, the vehicle is essentially a stretched Continental with rear doors that latch forward. Lincoln doesn't call it the suicide door edition, of course. No, the proper name is 80th Anniversary Coach Door Edition. Semantics aside, the car is here to pay homage to the suicide doors of the 1960s Continental and celebrate 80 years since the original Continental was introduced. That's the why; now here is the how. To build this special edition, a Continental begins life as a normal Black Label model, and leaves the factory with normal doors intact. From there, Lincoln ships the car to Cabot Coach Builders in Massachusetts for the stretch and other modifications we'll get into later. Before you start cursing Lincoln for not really screwing together a suicide door Continental, know this: Lincoln engineered all the components, metalwork and everything else that goes with the build. It then gives the car and components to Cabot for the fabrication work. So yes, somebody else is doing the conversion, but you're still getting a Lincoln-engineered vehicle. Make of that what you will. Cabot has done work for Ford before with the MKT and Transit Van, but Lincoln says it's much more involved in this build than it ever was before. To begin, the Continental gets a six-inch stretch. It was a relatively long car before, but boy does this thing look like it's lounging now. That's exactly what you'll be doing once inside those suicide doors. Lincoln claims best-in-class legroom, and yes, to our eye that is surely accurate. Someone well over 6 feet tall could easily stretch all the way out and still have room to spare back there. The only problem we noticed? Headroom. A sloping roofline combined with seats that are well pushed back doesn't leave a whole lot of space up there. It looks like Lincoln noticed this and carved out little spaces in the headliner, but it might not be enough for those who are closer to the sky than most. A flow-through center console occupies space where the middle seat would typically be. This has all sorts of controls for things like audio and climate control. Lincoln said the one we sat in wasn't entirely finished with all the features and electronics that will be included.

Ford Announces Four Recalls, 1.4M Vehicles Affected

Ford is taking a bit of the spotlight away from General Motors, announcing a major group of recall campaigns, covering a total of 1.4 million vehicles built between 2006 and 2013. Let's start with the big one, which covers the Ford Escape, Mercury Mariner and, according to The Detroit News, Ford-built Mazda Tribute CUVs. 915,216 vehicles are covered, all of which were built in model years 2008 to 2011. 736,000 vehicles are in the US, while Canada then Mexico make up the vast majority of the remainder. The problem is due to an issue with the torque sensor in the steering column, which could lead to sudden power steering failure. Manual steering would still be available, though. "Dealers will perform one of three service fixes, depending upon what diagnostic codes are shown when the vehicle is taken to the dealer," Ford spokeswoman Kelli Felker wrote to Autoblog in an email. "They will either update software for the power steering control module and the instrument cluster module; replace the torque sensor; or replace the steering column, which includes upgraded power steering control module software." The most recent generation of the Ford Explorer is suffering from a similar malady, thanks to an intermittent electrical connection (we think that means short circuit) in the steering column. Like the Escape and Mariner, manual steering would still be available in the event of a power failure. Ford will recall 195,527 examples of its Explorer, 177,500 of which are in the US. This recall covers model years 2011 to 2013. According to Automotive News, the National Highway Traffic Safety Administration has stated that Ford will inform owners of affected vehicles by July 25. Ford is also recalling 200,000 Taurus sedans, over a corrosion issue in the license plate lamp. This particular recall, which covers vehicles from model years 2010 to 2014, is limited to drivers in northern climes. Vehicle owners in southern states are free to pass on the recall. Finally, 82,576 Fusion, Mercury Milan and Lincoln Zephyr/MKZ sedans from 2006 to 2011 are being recalled because of floormats that can interfere with the accelerator pedal. Dealers will replace the offensive floormats with newer examples. "Ford is committed to providing our customers with top quality vehicles. We are equally committed to addressing potential issues and responding quickly for our customers," Felker wrote.