Ford Investing $600 Million To Produce Next-Generation Escape In Louisville

December 18, 2010


Ford Motor Company recently announced it is investing $600 million to transform its Louisville Assembly Plant into a modern, flexible facility that is building the next-generation Escape for the North America market starting late next year. 


The plant is the third North American body-on-frame truck plant that Ford is re-tooling to enable production of fuel-efficient products from its global vehicle platforms. Louisville Assembly has been building the Ford Explorer SUV since 1989.


Ford moved production of the all-new 2011 Explorer to Chicago Assembly and is overhauling the Louisville facility to build the next-generation Escape and providing future manufacturing flexibility. 


When the transformed Louisville Assembly Plant restarts production in 2011, it will operate on two shifts with approximately 2,900 employees – up from today’s one shift and approximately 1,100 employees. The 1,800 additional jobs are expected to be filled through a combination of transferring employees from other facilities, re-activating workers on indefinite layoff at the time of launch and hiring new workers. 


“Our Louisville Assembly Plant transformation further proves our commitment to American manufacturing and our commitment to deliver the high-quality, fuel-efficient vehicles people really want,” said Mark Fields, Ford’s president of The Americas. “Working closely with the UAW and Kentucky officials, we have found a way to competitively deliver an important new vehicle that is good for our customers and supports our plan to deliver a well-balanced product portfolio of cars, trucks and utilities.”


Ford will signal its future direction for the next-generation Escape through a concept vehicle debuting at the North American International Auto Show in January.


Later in the year, the plant reopens with tooling and facility upgrades in its final assembly area and body shop. Reprogrammable tooling in the body shop will allow the plant to produce multiple vehicle models at the same time without requiring downtime for tooling changeover – making Louisville Assembly Plant Ford’s most flexible high-volume plant in the world. 


With this new technology, Louisville Assembly can build up to six different vehicles at the same time, allowing Ford to meet demand more quickly in the event of potential shifting customer preferences dictated by changing economic conditions.


“Manufacturing flexibility is a key to competitiveness, and we are continually exploring ways to raise the bar in this critical area of the business,” said Jim Tetreault, Ford’s vice president of North America Manufacturing. “While we are launching Louisville Assembly Plant with one key product – the next-generation Ford Escape – we are building in the flexibility to produce other vehicles at the plant in the future, depending upon volume requirements, customer preferences and other factors that affect vehicle demand.”


The Commonwealth of Kentucky and the city of Louisville are key partners in strengthening the foundation for Ford’s commitment to American manufacturing in Louisville. Ford’s state and local partners have committed up to $240 million in tax incentives during the next 10 years, based on current and potential future investments and job creation at the company’s two Kentucky facilities – Louisville Assembly Plant and Kentucky Truck Plant.


Kentucky’s incentives are based upon an initial combined Ford investment at both facilities of about $800 million – the $600 million for Louisville Assembly transformation and the previously invested $200 million for accommodating Ford Expedition and Lincoln Navigator production at Kentucky Truck Plant. The incentive also allows for additional investment in the future.


“We are grateful to the Commonwealth of Kentucky and the city of Louisville for their support of Ford and our commitment to manufacturing here,” Fields said. “With Louisville Assembly Plant up and running next year, Ford will have nearly 6,600 employees in Kentucky, and the work we have done together makes this an important manufacturing center of excellence for us.”


“Kentucky takes great pride in its ongoing partnership with Ford Motor Company,” said Gov. Steve Beshear. “The transformation of the Louisville Assembly Plant demonstrates the depth of that relationship and the tremendous results that can occur when state and local government and the private sector work together. It is because of our relationship that the Commonwealth proactively approved an amended incentive package today that will create the flexibility to potentially increase Ford’s investment and jobs at Louisville Assembly Plant and Kentucky Truck Plant over time.”


Ford’s investment of $600 million in Louisville Assembly Plant for production of the next-generation Escape also is supported by the company’s green partnership with the U.S. Department of Energy. Louisville Assembly Plant is one of 11 Ford facilities in the U.S. participating in the Advanced Technology Vehicles Manufacturing Incentives Program initiated by Congress and implemented by the Obama administration. The program is helping to develop advanced technology vehicles and strengthen American manufacturing across the country.


“Only one word can capture the magnitude of today’s announcement – WOW,” said Louisville Mayor Jerry Abramson. “Ford is making a long-lasting investment in the company’s future in Louisville, Kentucky and a tremendous commitment to our citizens by dramatically expanding the number of good-paying jobs.”


Fuller Ford can help you find the most fuel efficient vehicle to fit your individual needs. As always, Fuller Ford offers Lifetime Free Oil Changes on ALL new vehicle purchases – in stock or factory ordered. Fuller Ford is the Cincinnati Tri-State Region’s leader for the hottest, cutting-edge, most fuel efficient vehicles available. Whether you are coming from Ohio, Kentucky, or Indiana, we are conveniently located right off of I-75, just west of downtown Cincinnati. Come in today to see Ford’s entire line of fuel efficient vehicles. Or, check out our inventory at





6.7L Diesel Engine Maintenance

December 16, 2010

6.7l diesel maintenance

Since the launch of the 2011 Super Duty, Ford Motor Company has made an effort to promote awareness of critical Power Stroke® diesel engine operating characteristics and maintenance requirements. It is imperative that 6.7L customers understand that more frequent maintenance is required when their vehicle is utilized under special operating conditions (towing, long idle/commercial delivery, off road/dusty, biodiesel).

  • Engine failures can occur due to lack of proper coolant strength and carboxylates level checks.
  • Turbocharger failures can occur due to a lack of proper lubrication or dusting from unfiltered intake air.
  • Turbocharger & EGR valve collect coking deposits faster in colder weather without proper maintenance.
  • Low fuel pressure and/or fuel volume due to fuel filter contamination can cause hard starting and slower cranking times.
  • Fuel injector internal failures can occur due to loss of fuel pressure from clogged filters, fuel line freeze up, and the injector spool valve can stick when the oil is contaminated and/or the wrong oil viscosity.


Maintenance frequency is also dependent on miles, engine idle hours, normal vs. severe service conditions, quality of materials used – primarily ULSD fuel, engine oil, air and oil filter element, coolant level and quality, etc. 6.7L customers must adhere to the maintenance interval guidelines using the Intelligent Oil Life Monitoring System, vehicle mileage OR engine idle hours, whichever is attained first. Engine idle hours of operation, accessed via the vehicle message center, are particularly important if the vehicle is used for periods of extended engine idling where vehicle mileage is not accrued.

  • Frequent or extended idling
    • Over 10 minutes per hour of idling
    • Frequent low speed operation
    • Sustained heavy traffic less then 25 MPH (40 KMH)
  • One hour of idle time is equal to approximately 25 miles (40 km) of driving
  • Operating in sustained ambient temperatures below -10°F (-23°C) or above 100°F (38°C)
  • Operating in severe dust or off-road conditions
  • Towing a trailer over 1,000 miles (1,600 km)
  • Sustained, high speed driving at Gross Vehicle Weight
  • Rating (maximum loaded weight for vehicle operation)
  • Use of any Biodiesel: B20 is the maximum allowable blend to be used with the 6.7L Power Stroke® Diesel


HOW TO CALCULATE EXTENDED IDLE CONDITIONS (Intelligent Oil Life Monitor does this automatically for you)
Engine Idle Hours vs. Vehicle Mileage Formula (Helpful to determine if “Extended Idle” condition exists)
Record the engine idle hours from the vehicle and multiply the number by 25 (1 hour of engine running time is equal to approximately 25 miles).


  • If the number is less than the miles on the odometer, the vehicle is driven more than it idles – use vehicle mileage to determine maintenance intervals (other than oil change intervals)
  • If the number is greater than the mileage on the odometer, the vehicle idles more than it is driven – use engine hours of operation to determine maintenance intervals


This system uses information from a sensor in the oil pan, the Powertrain Control Module and an algorithm to calculate the proper oil change interval. The interval is calculated based upon the vehicle operating conditions:


  • Engine speed & torque
  • Oil & Coolant temperature
  • Hours of operation and Mileage (Idle Hours and Total Hours)
  • Driving habits
  • Number of Diesel Particulate Filter regens or cleaning cycles


The system uses the Message Center to display when the oil needs to be changed:

  • “ENGINE OIL CHANGE SOON” at 5% oil life remaining
  • “OIL CHANGE REQUIRED” at 0% oil life remaining


The IOLM system applies to fuel filter replacement. At the 3rd oil change interval the IOLM system will notify the driver that the fuel filters must be replaced. Additionally, there is a sensor in the fuel line that informs the driver, via the instrument cluster, that the filter is becoming plugged before the 3rd oil change interval. 

This same Extended Engine Hours vs. vehicle mileage formula also applies to engine coolant when operated in special operating conditions. Check for Nitrite Contamination using Rotunda test strip 328-00001 and then the carboxylates level of the coolant using Antifreeze Coolant ELC Contamination Kit, Rotunda part number 328-00008. Add the VC-12 – Motorcraft® Specialty Orange Engine Coolant Revitalizer or replace the Motorcraft Specialty Orange coolant VC-3-B as necessary.

In addition, 6.7L customers should be aware that non-Ford maintenance products (engine oil and oil, air filters, fuel filters and engine coolant) may not provide an adequate level of protection due to varying levels of aftermarket production standards and processes. Please contact Fuller Ford’s service department for additional information on 6.7L Diesel Engine Maintenance @ (513) 352-5800 x 33 or check us out on the web @

As always, Fuller Ford offers Lifetime Free Oil Changes on ALL new vehicle purchases – in stock or factory ordered. This includes 6.7L Diesel! Fuller Ford is the Cincinnati Tri-State Region’s truck leader. Whether you are coming from Ohio, Kentucky, or Indiana, we are conveniently located right off of I-75, just west of downtown Cincinnati. Check out our entire inventory at





Engine Master

December 13, 2010

Fuller Ford is proud to announce that our very own, Dwayne Jacobs, has achieved Engine Master status through Ford’s 2010 Masters Program.  This is Dwayne’s first time to achieve this status. He is one of only 317 technicians in the Cincinnati Region who hold the Engine Master status.

As vehicle technology progresses, it requires increased levels of knowledge and skill for technicians to effectively complete advanced diagnostic and repair operations. Dwayne’s accomplishment demonstrates his support of Ford Motor Company and Fuller Ford’s joint commitment to highly trained personnel. Most importantly, this commitment fulfills our customers’ expectations that their vehicles are repaired by highly-skilled, factory-trained technicians.

Dwayne joins Chad Heidelberg, who previously achieved Senior Master status. Fuller Ford congratulates both Dwayne and Chad on their outstanding achievements

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