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What year did Ford Expedition go aluminum?

The Ford Expedition, the full-size SUV from the American automaker, made the switch to an aluminum body in 2015. This transition to a lighter, more fuel-efficient aluminum construction was a significant milestone for the Expedition and the broader automotive industry.


The Shift to Aluminum


In 2015, Ford unveiled the fourth-generation Expedition, which featured a body made primarily of aluminum alloy. This move was part of the company's broader strategy to reduce the weight of its vehicles and improve fuel efficiency across its lineup. The switch to aluminum allowed the Expedition to shed up to 300 pounds compared to the previous steel-bodied model.


The decision to use aluminum was driven by several factors, including the need to meet increasingly stringent fuel economy standards and consumer demand for more efficient and environmentally-friendly vehicles. Aluminum is not only lighter than steel, but it is also more corrosion-resistant and can be shaped into complex forms, making it an attractive material for automakers.


Benefits of the Aluminum Expedition


The transition to an aluminum body provided several benefits for the Ford Expedition:



  • Improved Fuel Efficiency: The weight reduction from the aluminum construction resulted in better fuel economy, with the 2015 Expedition achieving up to 24 mpg on the highway, a notable improvement over the previous model.

  • Enhanced Performance: The lighter weight also contributed to improved acceleration, handling, and towing capacity, making the Expedition more capable and responsive on the road.

  • Increased Durability: Aluminum is more resistant to corrosion and dents than steel, which can help extend the Expedition's lifespan and reduce maintenance costs over time.


The switch to aluminum was a significant investment for Ford, but it has paid off in the form of a more efficient, capable, and durable Expedition that has resonated with consumers.

Kevin's Auto

Kevin Bennett

Company Owner

Kevin Bennet is the founder and owner of Kevin's Autos, a leading automotive service provider in Australia. With a deep commitment to customer satisfaction and years of industry expertise, Kevin uses his blog to answer the most common questions posed by his customers. From maintenance tips to troubleshooting advice, Kevin's articles are designed to empower drivers with the knowledge they need to keep their vehicles running smoothly and safely.