Ford plants get ready to churn out the much-awaited F-150s

The first, much-awaited, 2015 F-150s to be delivered are coming from the company’s Dearborn, Mich., plant which has worked through early production glitches. Ford workers in Claycomo have been training to build it while continuing to make some of the older F-150s in the interim.

The Dearborn plant will be able to build 400,000 of the trucks when at full speed, and Claycomo’s capacity will be 300,000.

Ford says its Kansas City area plant will begin manufacturing the 2015 model early next year, but it hasn’t been more specific. It will start with one shift and ramp up to three. The Claycomo plant, which also makes the Transit commercial van, has about 6,000 employees. That’s a stark contrast to a few years ago when the plant lost the Ford Escape and the F-150 was down to one shift, spawning worries about the plant’s future.

The new F-150 will be up to 700 pounds lighter. The aluminum body, similar to what the military uses in its Humvee, accounts for the biggest part of the reduction. A lighter vehicle means it takes less energy to move it, and the opportunity to use a smaller engine. A turbocharged 2.7-liter V6 Ecoboost engine, which will cost an extra $500, is the most efficient engine in the 2015 F-150. A larger turbocharged V6 is also available, along with a traditional V6. A 5-liter V8 is offered, but the 6.2-liter V8 has been dropped.

The Environmental Protection Agency in its fuel economy standings gives the 2015 F-150 with the 2.7-liter engine a rating of 22 miles per gallon in combined city/highway driving. The best for the previous model was 19. The most efficient Chevrolet, GMC and Dodge full-size pickups with gasoline engines get 20 miles per gallon in the government ratings.

Engine size and power are sensitive issues for pickup trucks. Ford with its Ecoboost engines has increased the amount of horesepower and torque, and is making inroads into the turf of larger engines. But it still offers the V8 for the heaviest duty work and those who prefer a larger motor.

But Ford officials feel the 2.7-liter engine in the F-150 may be the sweet spot in getting new customers with improved economy and enough towing capacity to pull 8,500 pounds.