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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.

Ford recalling select Taurus, Explorer and Lincoln MKS models over fuel tanks

Ford is recalling certain 2012 Taurus, 2013 Explorer and 2012 Lincoln MKS models over fuel tank concerns. According to the National Highway Traffic Safety Administration, vehicles built between July 19, 2011 and March 15, 2012 may have been built with fuel tanks that have a "marginally sealed seam" on the side. Those seams may not provide the strength necessary to protect the tank from rupture during a collision. They may also leak. The recall covers a total of 3,037 vehicles. NHTSA says that leaked fuel, in the presence of an ignition source, could easily cause a fire.
Dealers will inspect the tanks and replace them as need be free of charge. Owners can expect to be notified once the campaign begins on or around April 22, 2013. You can read the full NHTSA recall notice below for more information.

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.