This was posted in this other thread. No specifics for the exact reasons, but good evidence of what Ford has done in the past.

Check this part of AAI out. (Find the green arrow)

 

Started looking locally for dealer inventories, and for some reason, all the dealers close to me got swamped with cars in the past week. Looks like things are finally starting to really move now, so hopefully we can continue this streak for weeks to come.

 

That would be the most common reason; and apart from say, an accident in the plant (like a forkift running into the side or a shipping yard accident) that would be the only reason.

Keep in mind, that the body construction process is highly automated now. Many parts have very little human contact -- the dimensional and welding processes are done by robot and machine tooling. Dimensional checking is done by a machine. Now, there are many things that are done using sensors looking for bad or misaligned parts, but occasionally in rare instances strange things do happen.

Most times these issues are caught long before the car is built fully and trimmed out. And while I cannot say for certain what happened with these particular cars, it is quite possible that it was something that didn't show up until the leak test (water test). And if it was found that the cause of the leak was a miswelded panel and they couldn't fix it (a shifted floor pan could be one) they would scrap the VIN; they would possibly campaign all vehicles on site for this same issue. And at the same time they would also try to re-engineer the process back in the body shop to avoid the issue from reoccuring. ie put in more sensors. We term it in the field as "foolproofing"

It is possible that sheet metal changes for the '11s left gap in the foolproofing system, and a few got through.

 

the new dealer just called AGAIN!..

2 GT's on the truck.. neither of them are mine..
they were for my old dealer other orders which again were after mine ..

so fingers are crossed..

 

Well at least the new dealer is calling you now?...

 

from no calls in over a month from anyone.. to 4 in one day..

the pesimist in me says my car is still sitting in AAI somewhere in flat rock.

 

I'll be taking a trip through AAI tomorrow and will keep an eye out for large piles of unshipped cars. I will also try to figure out which lots are what when I'm in there.

 

Yeah, same here.

Requested deposite back, I'll see it in the mail soon

Knowing my luck, it will show up the day after I pick-up the Camaro

 

Mine, is still there. Waiting to be shipped, supposed to be here by the end of the month.....

 

The limit of effort my new salesman would offer was to alert me when my vehicle arrived.

On the fourth request, where my distain for his lack of effort was dripping off the E-Mail, he bounced it up to the manager. The manager informed me my vehicle was completed on June 6 and would arrive at the end of the month.

He confirmed all vehicles were on hold regardless of issues, but all would arrive at the end of the month.

I agree that the factory should only ship good vehicles and should repair the problems first. I am not walking so I don't mind the delay.

I do mind the absence of communication from the factory. Who did they think they were going to fool? They should "come clean" w/ an official notice.

 

They will...an offical TSB or recall notice

 

If there were an official notice and more precise time frame (ala realistic ETA) I would have kept my order as long as it met my deadline (7/9/10). This end of the month June/July stuff doesn't work for me. I understand padding times and working within a window, but a firm end of June delivery keeps my business, a unconfirmed late July does not.

 

While you're there Steve, could you please take a close look at ramp 51 to see if my car is still rusting out there. Thx. Take a few quick photos as well if you can ! Don't worry, we'll bail you out.

 

If you see a red Shelby with black accents, thats mine. Cant be too many with that combination. Anyway tell him to come on home if you see him.

 

I got a firm end of June from my Dealer today for what it's worth....

 

I feel like this wasn't meant to be... I know this is out of my dealers hands, but I wouldn't take this being passed over crap at a McDonald's, why should I accept it on something costing 10,000 times more?

I equate this to me ordering a Big Mac Meal and waiting off to the side while the next few people order their food. Some order a Chicken Nugget Meal, others order a Quarter Pounder Meal with a few that order the same Big Mac Meal... some with special requests like "hold the special sauce". All of which get their food before me

I guess the big difference is that you pay in full while you wait for your food at McDonald's.

 

And the difference is the Big Mac doesn't have hundreds of parts being supplied from all over world.

When I worked at taco bell we used to call tickets out of order all the time. We didn't call them based on who ordered first, we called based on which was more convenient for us to make first

 

Thanks for the detailed explanation Sparky. If you don't mind my asking, what kind of work are you doing for Ford? (I would totally understand if you want to maintain your anonymity)

 

If it was a sheet metal issue then it had to be a fluke ... it's all the same as the 2010's ... Guess I better check my floor pans!

 

OAC= Oakville Assembly Complex
Sparky= Old term referring to an electrician

I work in the bodybuild area of the plant that makes the Ford Edge, Flex and Lincoln MkX and MkT.

By trade I am an electrician (with a tool and die background), the official title is "Electrical Weld Repair Technician". I work maintenance on all electrical equipment in the plant from conveyors to tooling to automated welding equipment to programming robots to programming PLC and machine controls. It's a broad spectrum.