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Ford News: 2020 Explorer and Aviator Quality Issues Hit Ford


Drew Dowdell

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The 2020 Ford Explorer and 2020 Lincoln Aviator are likely the most important vehicles in Ford's lineup after the F-150.  These new SUVs mark a turn for Ford in styling and technology. The problem is, early reports indicate that there is trouble brewing in Chicago, the plant where they are built.

The two SUVs are just now arriving at dealerships, but have already been the subject of recalls for seats, missing manual park release covers, and other issues.  The issues have become so bad that Ford is trucking them from Chicago to their Flat Rock Assembly for further examination.  Dealers around the country have been notified of delays on their shipments due to unspecified manufacturing issues.  Ford is providing no details on the subject.

A Ford source involved with the repairs says that Ford is using X-Ray to try and diagnose chassis issues, transmission issues where the vehicle doesn't properly go into Park or not properly activating the parking brake leading to the possibility of a roll-away, air-conditioning systems that blow heat only, Aviators with automatic suspension issues where the vehicle arrives in suspension failure mode, and transmissions that leak so much fluid "it looks like a crime scene".  Aside from the serious issues, even the mundane issues appear; missing badges and trim, or having the wrong wheels. 

Ford has called in workers from plants in Kentucky, Dearborn, Wayne, and Sterling Heights to help at Flat Rock to complete repairs. Flat Rock normally builds Mustangs and Continentals, but from Friday to Sunday, workers spend their time processing Explorers and Aviators. 

Ford can't stop production of the vehicles even though they have a build-up of thousands of defective vehicles because the revenue is booked when the vehicle leaves the plant. Stopping production would reduce book revenue this quarter. Ford already was downgraded to junk bond status earlier this week.


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This has been a trainwreck of a product launch. 

2 hours ago, Drew Dowdell said:

At least they're catching it before it makes it to the customer. I'll give Ford credit for that. 

Very true but they need better communication with their dealers to relay messages to customers. As of now the dealers are left in the dark and the customers' vehicles are being delayed and they have no answer of why or when they'll get them. 

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4 hours ago, dfelt said:

Ouch, this is not good for hoping to get people to forget that FORD = Fix or Repair Daily.

Ah, back to the 1970s.  Sometimes I wonder if Ford has consistently ever learned NOT to screw up, especially on brand new product meant to save the company.

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2 minutes ago, Paolino said:

How are some of these problems even happening?  I mean, it's 2019... how are vehicles even leaving without badges and trim?!

Sounds like Ford is really cutting corners on QA/QC in some of their plants...

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28 minutes ago, Paolino said:

How are some of these problems even happening?  I mean, it's 2019... how are vehicles even leaving without badges and trim?!

Right! and how the hell does an auto get built today that is leaking like a faucet on fluids from the assembly line. This is just pathetic.

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41 minutes ago, dfelt said:

Right! and how the hell does an auto get built today that is leaking like a faucet on fluids from the assembly line. This is just pathetic.

I don't get it honestly.

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8 hours ago, Drew Dowdell said:

At least they're catching it before it makes it to the customer. I'll give Ford credit for that. 

Well, Ford can't really sell a faulty product right out of the factory that doesn't go into park and override parameters don't kick in and the car rolls away, for crying out loud. On top of all the other issues like chassis cracks they are x-raying for and AC that blows heat (wouldn't work here in AZ) and the Lincoln's suspension in failure mode when it's delivered to the dealer, jeez. No chance for the public to get one if it's not ready for prime time or to safely sell. I give Ford ZERO credit, they need these SUV's to be good to survive, especially after they cancelled all car production. Ford's CEO Hacket is a Hack, if the shoe fits, wear it.  

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3 hours ago, dfelt said:

Right! and how the hell does an auto get built today that is leaking like a faucet on fluids from the assembly line. This is just pathetic.

It's like all the shift supervisors quit and everyone else is high or drunk at the factory :)) 

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1 hour ago, USA-1 Vortec 6.2 said:

It's like all the shift supervisors quit and everyone else is high or drunk at the factory :)) 

I do recall a friend who worked at the Oakville Ford plant saying a fair number of empties ended up in the door cavities on Friday cars..

 

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15 hours ago, USA-1 Vortec 6.2 said:

Well, Ford can't really sell a faulty product right out of the factory that doesn't go into park and override parameters don't kick in and the car rolls away, for crying out loud. On top of all the other issues like chassis cracks they are x-raying for and AC that blows heat (wouldn't work here in AZ) and the Lincoln's suspension in failure mode when it's delivered to the dealer, jeez. No chance for the public to get one if it's not ready for prime time or to safely sell. I give Ford ZERO credit, they need these SUV's to be good to survive, especially after they cancelled all car production. Ford's CEO Hacket is a Hack, if the shoe fits, wear it.  

I was comparing to Tesla who just ships it with stuff wrong anyway. 

14 hours ago, smk4565 said:

And this Aviator is supposed to challenge the X5 and Q7?  Good luck with that.

Once they get the issues fixed, I genuinely believe it will. 

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Good point, Tesla is a mess, it's like the QC dept. left for lunch and never came back. The fit and finish is not where it should be for 2019 either, I think Tesla interiors are bland especially for the price point.

I remember even the last Gen. Explorer had issues with crack exhaust manifolds to where occupants were getting sick from CO2 gases getting into the cabin, and again FoMoCo never really admitted the real flaw in the design, said it was door seals or holes in the doors letting exhaust in and had dealers seal off the door holes but still are having issues with CO2 leaking in, that's ridiculous CO2 is a heavy gas it doesn't float up into cracks or holes in the doors it gets in through the fire wall and into the HVAC system when driving down the road because the exhaust manifolds are seeping. I read citizens as well as several city police depts. are suing Ford because they had several officers sick and some on sick leave because the CO2 poisoning really hit them hard. So this new batch of issues is not good and really damaging. FoMoCo needs to wake up!!     

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4 hours ago, Drew Dowdell said:

I was comparing to Tesla who just ships it with stuff wrong anyway. 

Once they get the issues fixed, I genuinely believe it will. 

 

18 hours ago, smk4565 said:

And this Aviator is supposed to challenge the X5 and Q7?  Good luck with that.

There's a lot of damage control going on at Ford right now especially for an all new model, not a good arrival FoMoCo.

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