Ford Begins Building New, Aluminum-Body F-150

DEARBORN — Ford Motor Co. Tuesday said the first all-new 2015 Ford F-150 pickup truck rolled off the line at its Rouge Center assembly plant.

The truck, revealed at the 2014 North American International Auto Show, is the first in its class to have an aluminum alloy body and bed.

The new F-150 will go on sale in December in the United States and will spread to 90 other nations by 2015.

More than 225,000 people have submitted contact information for updates about the vehicle, and more than 250,000 customers have built and priced their own unique version of the all-new F-150 online – a record through 13 generations of America’s favorite truck.

Ford’s refurbished Dearborn Diversified, Stamping and Tool & Die facilities provide the latest equipment to give the truck its tough body. This includes new press lines to help stamp four different types of high-strength aluminum alloys that reduce cab and cargo box weight while improving durability. New hydroforming lines use pressurized oil to form metal tubes into strong support rails for structural soundness, a new chemical coating system prepares the aluminum for high-strength adhesives, and a new heat treat area bake hardens the alloys, resulting in more robust, durable materials.

Five hundred new robots in the all-new body shop use advanced joining technology that leads to a tougher truck. Smaller, more compact robots install the roof and doors, transfer the vehicle to final assembly, and scan the body to ensure the highest quality standards are met.

The Dearborn Truck Plant paint shop was updated with dirt detection technology and increased robotic paint automation for more durable paint application. Other new processes support the addition of new truck features, such as installation of a class-exclusive 360-degree camera with split-view display.

To support the launch of the all-new F-150, Ford added 850 new workers across its Dearborn Truck, Diversified and Stamping facilities. These new workers join the more than 4,000 existing employees.

Due to its weight savings and engine technology. the new F-150 can tow up to 1,100 more pounds, haul up to 530 more pounds, and will have better fuel economy ratings than the current lineup. Fuel economy is projected to be at least 5 percent and up to 20 percent higher. (EPA-estimated fuel economy ratings will be announced later this month.)

The new truck also features 400-watt power outlets inside the cab; LED headlights, taillights and sideview mirror spotlights; remote tailgate release; best-in-class towing of 12,200 pounds; and best-in-class payload of 3,300 pounds.

In addition to the Dearborn Truck Plant, the all-new F-150 will be manufactured at Kansas City Assembly Plant in Claycomo, Mo., starting in the first quarter of 2015. Combined, the two plants will have capacity to produce more than 700,000 trucks per year.

Visitors can plan to witness production of the all-new F-150 as part of the Ford Rouge Factory Tour in Dearborn. The tour is undergoing renovation, with new films, exhibits and hands-on experiences scheduled to reopen to the public later this month.

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