Ford has given additional details about how it achieved an approximately 700-pound weight reduction on its 2015 F-150 truck beyond its use of military-grade aluminum in the body panels.
As expected, the majority of the weight loss (450 pounds) came when Ford replaced steel doors, roof, hood, and other body panels with aluminum parts. Using high-strength steel throughout the frame also helped reduce weight. However, Ford removed an additional 250 pounds by replacing components in the seats, parking brake, and steering knuckles.
Ford found significant weight savings with other exterior components. Ford reduced 13.7 pounds with aluminum fenders, 35 pounds with a smaller rear axle that received internal improvements to increase trailering, and 26.9 pounds with a lighter weight electronic parking brake. The new parking brake adds smart features such as driveway release and dynamic four-wheel braking with ABS.
Ford also saved 3.8 pounds with a magnesium transfer case, 23.1 pounds with two aluminum steering knuckles that allow the wheels to turn and move vertically for dips and bumps, and 2.7 pounds with a lighter 4x2 front bumper.
On the interior of the truck, Ford engineers focused their attention on the seating, instrument panel surface, and sub-system. Ford reduced the weight of the front seating by 31.7 pounds and rear seating by 14.7 pounds. A unique coating on the instrument panel surface reduces glare and new design allows for bigger instrument cluster and center-stack displays for a 2.5-pound weight savings.