Alcan Aluminum Helps Lighten the Load on 2003 Ford Expedition and Navigator

DETROIT, June 27 -- Ford Motor Company's redesigned Expedition and Lincoln Navigator sport utility vehicles feature the automaker's first aluminum liftgate produced in North America. The full-size SUVs take advantage of aluminum's light weight to offer a rear liftgate that weighs nearly 40% less than a conventional steel product, making it easier to raise and lower.

Ford began shipping the 2003 Expeditions and Navigators in May from its Michigan Truck Assembly plant in Wayne, Mich.

The liftgate was developed by Ford in partnership with Alcan Automotive, a leading supplier of aluminum automotive products and technology, based in Farmington Hills, Mich. Alcan has been awarded the supply contract for aluminum stamping blanks.

From concept through launch, Alcan was an integral partner to Ford on the liftgate project, participating in both the engineering and manufacturing teams. The liftgate features a multi-alloy design, engineered to meet Ford's requirements for cost efficiency, formability, dent resistance and structural strength.

The liftgate is produced at Ford's Woodhaven facility, south of Detroit. The finished assembly weighs approximately 29 pounds, about 18 pounds less than a conventional liftgate. The reduced weight allows Ford to use lighter and less-costly gas struts, which provides secondary weight savings, and helps the vehicles to achieve their targeted weight class.

Most important for Expedition and Navigator owners, the liftgate is strong and sturdy, yet easy to operate. On the Navigator, these features also contribute to a power-operated liftgate that raises and lowers quickly at the click of a button.

Alcan Automotive is a world leader in the supply of aluminum-based solutions for the automotive and mass transportation markets. Its parent company, Alcan Inc., is a multinational, market-driven company and a global leader in aluminum and specialty packaging with 2001 revenues of $12.6- billion. With world-class operations in primary aluminum and fabricated aluminum, as well as flexible and specialty packaging, Alcan is well positioned to meet and exceed its customers' needs for innovative solutions and service. Alcan employs 48,000 people and has operating facilities in 38 countries.