P.A. Schilke back stories

KJRR

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Done! The (almost) complete list of P. A. Schilke back stories.

This idea was suggested a while back and it's been fun to read all the stories I didn't catch the first time.

Thank you to Phil for so generously sharing your experiences and knowledge!
I couldn't imagine the forum being as successful without you!

Here is the forum search:
Search results for back story by P.A.Schilke

Not sure I captured them all and will continue to search for any I missed and new ones too.

Feel free to add any you find or fix any that need it.

Enjoy!

  1. The History of the Saleen Race Trucks- the title says it all
  2. Aerostar - 1990 Aerostar All Wheel Drive Launch
  3. Ranger Ultra Utility Flatbed - 1997 Ford Ranger Ultra Utility Flatbed concept
  4. Shirt - Ford Racing - Ford Off Road Racing
  5. cambered rear axle - SCCA Racing testing Picture of the truck
  6. NASCAR - Daytona Ford Corporate Suite
  7. Old Ranger cup holder - Ranger started life with no real though for cup holders back in 1982¾
  8. Alternator Noise - what was the root cause
  9. Offroad - teaching how to drive off road in an Advanced Off Road School
  10. Cargo lights - amber light facing rearward
  11. Interference engine - 1981 Escort 1.6L
  12. One piece driveshaft - Econoline
  13. 911 20 Years Later- Ranger FX4
  14. SuperCooling package (also here) (and here) - F-series unusual uses
  15. Ranger - Vehicle growth
  16. Thick steering wheels (also here)- Donkeys and Needles :giggle:
  17. Lugnuts (and here)- wheel covers
  18. wheels (and here)- 4x4 wheels separating from vehicle
  19. Red Georgia Clay - SCCA Race trucks
  20. Brid strikes - SCCA Race trucks
  21. Ranger Edge (and here) - step bar
  22. Drop in bedliner - 4G Ranger Regular cabs had a low frequency loud moan
  23. Woodward Dream Cruise
  24. Cost reductions - Doing it the hard way
  25. Electric Aerostar - increased energy density battery in 1988
  26. Military vehicle prototype - F350 Crew Cab
  27. Harley Hauler
  28. Same keys - similar Econoline vans
  29. 2002 Ranger Launch - wrong color mix plastics
  30. BFG tires - Ford's offroad Racing
  31. Frame Cracking and here and here - various cracked frame stories
  32. Engineer training - understanding the whole system
  33. Mud - Ford's Off-Road Racing
  34. '62 Rambler - Magic fluid
  35. Lee Iacocca - exposed screws
  36. Oil Change -Torino
  37. Transfer case - attention to detail
  38. Lockheed WindTunnel (and here) - Steve Saleen
  39. VP Hydrocarbons - SCCA Truck Race
  40. body and assembly engineers - Union
  41. front torsen diff vs an open front diff - FX4, the original prototypes
  42. Speedo errors more speedo - got rid of cables way back in 1985
  43. Robby Gordon - Dakar and IndyCar race in Motegi Japan
  44. Ford GT - Ferrari Testarosa
  45. Rail test - single point crash sensor
  46. A4LD Transmission (and here) - durability
  47. Back Story On the FX4 Brand - how the FX4 Brand came about
  48. AWD/4WD - build 6 AWD F250s
  49. new prototype vehicle - not a positive experience
  50. Clocks - not Ford related but still a good story
  51. handling track - helmet sizes
  52. Boneyard tour - another cool story and planes
  53. button pusher - snow and sunroofs
  54. 460 Cid exhaust problem - Golden Exhaust system
  55. Axle flip - overslung to underslung
  56. Livernoise - custom radiators
  57. Mitsubishi Diesel (and here) (and here) - the Ranger with Mitsubishi Diesel
  58. DOT 5 brake fluid - neighbors '62 'vette
  59. working on prototypes - DIY
  60. 1910 Ice Box - Why you should sit on your hands at an auction
  61. sophisticated equipment - Using clay to measure clearance
  62. Bronco II - CR stability testing
  63. rubber mat special- what are the options
  64. pedal package- Size 18?
  65. 4 spare tires - things seen in AZ
  66. Ranger in South America - changing tastes in vehicles
  67. pinstriping - Kansas City Assembly
  68. low mounted alternator (and here) - How engine components select their position on the engine.
  69. Belt Minder (Seat belts) -testing the disable function
  70. AZ MDV - Vision test
  71. twin I beam - alignment changing during shipping
  72. Product Design Graphics System (PDGS) - transitioning from drafting layouts to CAD and how it relates to Sync
  73. Spray in bedliner - how testing turned it into a black gooey mess
  74. tailgate white letters - how its done
  75. spindle design - Take prudent risks. Think out of the box. Do not be afraid to fail.
  76. TRPO - Ford truck camper
  77. Child seats - ever changing seat design
  78. wheel offset - how it may affect handling and tire wear
  79. Arizona dust - and condoms on an expense report
  80. OEM and aftermarket - for a particular tire size there were two different constructions
  81. potty patrol - sometimes we don't get the whole backstory and that may not be a bad thing...
  82. Design Verification and Proveout Report - just the facts
  83. Molson Indy in Toronto - running afoul of the law
  84. ABS - Does it help in off roadracing?
  85. Supplier Quality Assurance - The reason I advocate filing with Ford Customer Care
  86. golf tees - Not just for holding your balls
  87. step bars - and Ford Attorneys
  88. dinner bell sound - Pre-Production Product Proveout on the 460
  89. Where is your leak - using all your senses to find it
  90. Tumblehome - Why my seat gets wet with snow and rain
  91. beating moan condition - E350 with 460
  92. Ford programs names - RAM (another RAM story)
  93. Castellated Nuts and Cotter pins- taper engagement
  94. Error Codes - parts swapping
  95. Electrical wiring (also here) (and here) - Don't use solder or ScotchLoc
  96. Ford Lightning - selling to management
  97. carbon fiber leaf spring - failed springs
  98. phenolic timing gear (also here) - how it took the Duce to change it
  99. Firestone Wilderness AT - finding a replacement
  100. Road and Track Article - read the article and whole thread...
  101. Gauge Package - analog idiot lights pretending to be a gauge
  102. Tire pressure - use a quality gauge
  103. diamond stitch - what stuffing not to use
  104. shocks - don't abuse the jounce bumper
  105. rear shock exploded - finding the design flaw
  106. Tremor (and here) - terrible rattle in the cab
  107. Fiamm horns - Purchasing decided that maybe we should source horns...
  108. styled steel wheels - we wanted to get rid of the painted wheels...
  109. dressed to the 9's - A bosses reward
  110. vent windows and here - how to break into a F Series truck
  111. Document, Document, Document - more importantly...follow the test procedure
  112. REVOLUTIONARY FUEL ECONOMY IMPROVEMENT - Gas Wiz
  113. fording water - watch out for bow wave
  114. EPA letter to HFII - P.A.S sleuthing saves a recall
  115. story about cows - Ford truck did not have any power
  116. dealer swapped parts - do you have parts off another vehicle on the dealers lot?
  117. ZERO options truck - Manual steering, Manual brakes, a 4-speed manual trans
  118. aluminum wheels from China - assembly line issues
  119. drive a stick story - also heal-toe in an Aerostar?
  120. Bad gas story - avoid cut rate gas stations
  121. Yellowstone National Park - where the buffalo roam
  122. dissimilar spare - Ford Handling Track tested
  123. Ranger Edge - Design, engineering and testing
  124. Alignment, pull to the left - Experimental Garage alignment rack
  125. two piece driveline - not so good vibrations
  126. EPA and vacuum lines - Also reason for automatic Start/stop
  127. auto stop start - Flywheel variety
  128. Foutz Motorsports - Side by Side quad frame
  129. Aerostar - shiny binnacle cover
  130. driveshaft loop - why they are needed
  131. rodent problem - the well-travelled field mouse
  132. polarizing film - NASCAR windshields
  133. Firestone fiasco - finding a replacement
  134. crash tests - the first is always the best
  135. seating - inflatable lumbar and where to locate the bulb
  136. Shackle brackets - off road racing improved
  137. Greenhorn - Ford Graduate Trainee gets his tools
  138. Davis Dam testing - Cherry red exhaust but no overheating
  139. commercial for Ford Tough - would be great to find this commercial
  140. Ford chassis Motorhomes (and here) - Ford requirements of any RV manufacturer and how it relates to tunes
  141. 2.3L structural oil pan (and here) - knock sensor
  142. Ferrari TestaRosa - slick as goose sh!t
  143. Livernois Motorsports - relation with Ford and evolving as a company
  144. taking cost out of the Ranger - gap hiders, understand how it happens
  145. Helmholtz tuner - oil filter can mounted to the air cleaner
  146. mechanics Stethoscope - tracking down noises
  147. convex mirrors - original experimental mirror
  148. Cigar lighter - Never was a cigarette lighter
  149. Common Chassis program and here - Ford Light Truck, F Series and a Econoline, effort
  150. fracture analysis - twin I beam suspension
  151. Ford pranks - loud radios and banging wrenches
  152. 2001 SEMA show - solving vendor problems
  153. seating design - not just in vehicles
  154. ZZ Top - RangerZilla fix
  155. Towing - good information here
  156. Aerostar signoff Drive - 4 banger Dodge Caravan
  157. aspiring engineer - little ball on the top of the aerial
  158. Mazda B2000 - leather seats
  159. assembly plant - the smell of a newborn Ranger
  160. hot air balloonist - business card collector
  161. grab handle - alternative motives
  162. Pacific Coast Highway (PCH) - In an RV
  163. Baja 1000 - Helmet lift
  164. drop in bed liner - is it worth removing
  165. Cruise control - unsophisticated that at low speeds
  166. Camo removed - naked Aerostar makes the auto mags
  167. Pacifico - nectar of the gods at the Baja 1000
  168. why do you tape ducks - You only need two things in the shop
  169. vehicle NVH - on the line fix
  170. Usui fan clutch - eliminating the fan noise on the cheap
  171. Sirius Radio in the Ranger - how it relates to French rockets
  172. Left foot braker - pedal spacing
  173. pedal spacing - Aerostar big foot story
  174. block heaters - how to prevent your extension cord from being stolen
  175. Blackwood - a little insight into the Lincoln pickup
  176. Mr. Fixit - giving back
  177. Le Mans - broken transmission input shafts
  178. Aerostar 2.8L Manual trans - early preview at a dealership
  179. Ranger 2.0L motor - not a favorite motor
  180. part numbers - 2 stories for 1 post
  181. Antilock Brakes - rollover Ranger
  182. tall sides of the pickup box - who has the deepest bed
  183. cold testing - The power of the mighty 2.0
  184. blade adjustable sway bars - how they work
  185. EEC IV - short story on the first truck in Ford's history to have EFI
  186. Ford's off-road racing - short story on mid-west off-road racing
  187. sway bar diameters - Craftsman Truck series story
  188. Mazda 5 speed transmission - Racing improved
  189. PROCO...Programed combustion - DI
  190. static/dynamic loads - No need for figs
  191. rear wheels turning green - Exhaust
  192. Head gaskets - 3 suppliers
  193. renaming Special Vehicle Operations (SVO) - Ford Advanced Racing Technology?
  194. Ranger cracked frame - stiff shocks
  195. wiring harness - recall story
  196. headboard logo - how it came to be (race truck pics too!)
  197. backstory story - so glad you pushed ahead with posting these stories! Now to get the PDFs
  198. SHO Ranger - almost missed this one!
  199. added features - how you may get more than you purchased
  200. lost wheel - racing story tied back to production
  201. Never Forget - 9/11 support by FX4 Pre Production
  202. Dealer Flat Rate - Determine how it is determined
  203. Windstar Rear Axle Ripped out of the Prototype Garbage in equals garbage out
  204. Flat Track testing/wheel failure Testing wheel attachment
  205. Frozen EGR Transducer - How fast-food helped in cold weather developement
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TN Ranger

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I've enjoyed reading most of these posts. Can't say I've read them all. You always bring up great points and are a great resource for some Ford knowledge. Glad your around here to help out and offer suggestions
 

Dr. Zaius

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This idea was suggested a while back and no better time than now to start it...
Here is the forum searches
Search results for back story by P.A.Schilke

I'll link just the Ford related stories, no order, just as I found them.
Feel free to edit and add...

The History of the Saleen Race Trucks- the title says it all
Aerostar- 1990 Aerostar All Wheel Drive Launch
Ranger Ultra Utility Flatbed - 1997 Ford Ranger Ultra Utility Flatbed concept
Shirt - Ford Racing - Ford Off Road Racing
cambered rear axle- SCCA Racing testing
NASCAR - Daytona Ford Corporate Suite
Old Ranger cup holder- Ranger started life with no real though for cup holders back in 1982¾
Alternator Noise - what was the root cause
Offroad - teaching how to drive off road in an Advanced Off Road School
Cargo lights - amber light facing rearward
Interference engine - 1981 Escort 1.6L
One piece driveshaft - Econoline
911 20 Years Later- Ranger FX4
SuperCooling package - F150
Ranger - Vehicle growth
Thick steering wheels- Donkeys and Needles :giggle:
Lugnuts - wheel covers
wheels- 4x4 wheels separating from vehicle
Red Georgia Clay - SCCA Race trucks
Brid strikes - SCCA Race trucks
Ranger Edge - step bar
Drop in bedliner - 4G Ranger Regular cabs had a low frequency loud moan
Woodward Dream Cruise
Cost reductions - Doing it the hard way
Electric Aerostar - increased energy density battery in 1988
Military vehicle prototype - F350 Crew Cab
Harley Hauler
Same keys - similar Econoline vans
2002 Ranger Launch - wrong color mix plastics
BFG tires - Ford's offroad Racing


Went through 2 pages and 11 more to go...
Thanks for compiling this!
 

AzScorpion

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This idea was suggested a while back and no better time than now to start it...
Here is the forum searches
Search results for back story by P.A.Schilke

I'll link just the Ford related stories, no order, just as I found them.
Feel free to edit and add...

The History of the Saleen Race Trucks- the title says it all
Aerostar- 1990 Aerostar All Wheel Drive Launch
Ranger Ultra Utility Flatbed - 1997 Ford Ranger Ultra Utility Flatbed concept
Shirt - Ford Racing - Ford Off Road Racing
cambered rear axle- SCCA Racing testing
NASCAR - Daytona Ford Corporate Suite
Old Ranger cup holder- Ranger started life with no real though for cup holders back in 1982¾
Alternator Noise - what was the root cause
Offroad - teaching how to drive off road in an Advanced Off Road School
Cargo lights - amber light facing rearward
Interference engine - 1981 Escort 1.6L
One piece driveshaft - Econoline
911 20 Years Later- Ranger FX4
SuperCooling package - F150
Ranger - Vehicle growth
Thick steering wheels- Donkeys and Needles :giggle:
Lugnuts - wheel covers
wheels- 4x4 wheels separating from vehicle
Red Georgia Clay - SCCA Race trucks
Brid strikes - SCCA Race trucks
Ranger Edge - step bar
Drop in bedliner - 4G Ranger Regular cabs had a low frequency loud moan
Woodward Dream Cruise
Cost reductions - Doing it the hard way
Electric Aerostar - increased energy density battery in 1988
Military vehicle prototype - F350 Crew Cab
Harley Hauler
Same keys - similar Econoline vans
2002 Ranger Launch - wrong color mix plastics
BFG tires - Ford's offroad Racing


Went through 2 pages and 11 more to go...
Here I thought I had a lot of time on my hands. :whew::D
 

wanted33

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Phil has forgot more about Fords than I'll ever know. I would bet if he wrote a book about his time with Ford it would be a best seller.
 


Trigganometry

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Something taco owners will NEVER have! Their own resident expert!

Actually that’s not a bad idea at all, should write a book about a lifetime of experience. It would sell for sure!

Thank you for collecting all the links and posting them in one place.
 

DakotaGuy

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So Phil if you’re reading this I’d love to know when you started as an engineer on the Ranger program. Was it back at the very beginning or later? The reason I ask is because there are some very interesting documents that are floating around on the internet about the engineers vs management (bean counters) when it came to decisions about the stability of the Bronco II at the time. I read some of those old scanned internal documents and the engineers really wanted to make “real”changes to the vehicle to improve it’s stability, but management seemed to say no to the real fixes and just make minor adjustments. In the end, we all know how that little tippy SUV hurt Ford’s reputation and killed and injured people. I even know a family who lost their mom in a BII rollover back in the late 80s. There are also a few other documents that state later on when the first gen Explorer was being developed the engineers told management they wanted the archaic twin-traction beam and twin I beam replaced with a modern SLA front end as soon as possible. Management seemed to want to wait on a better suspension because of cost.

I know these two vehicles (Bronco II and early gen Explorer) are pretty legally toxic to Ford so all old engineers might be gagged for life about them, but I think it proves a point. So many times we might complain about how the engineers do something, but it’s not the engineers. In all of the cases related to the early Ranger based SUVs the engineers really wanted to do it right, but the bean counters wouldn’t let them. Even if you weren’t directly involved with these vehicle programs I bet you still have some stories about engineers frustration with that.
 

P. A. Schilke

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So Phil if you’re reading this I’d love to know when you started as an engineer on the Ranger program. Was it back at the very beginning or later? The reason I ask is because there are some very interesting documents that are floating around on the internet about the engineers vs management (bean counters) when it came to decisions about the stability of the Bronco II at the time. I read some of those old scanned internal documents and the engineers really wanted to make “real”changes to the vehicle to improve it’s stability, but management seemed to say no to the real fixes and just make minor adjustments. In the end, we all know how that little tippy SUV hurt Ford’s reputation and killed and injured people. I even know a family who lost their mom in a BII rollover back in the late 80s. There are also a few other documents that state later on when the first gen Explorer was being developed the engineers told management they wanted the archaic twin-traction beam and twin I beam replaced with a modern SLA front end as soon as possible. Management seemed to want to wait on a better suspension because of cost.

I know these two vehicles (Bronco II and early gen Explorer) are pretty legally toxic to Ford so all old engineers might be gagged for life about them, but I think it proves a point. So many times we might complain about how the engineers do something, but it’s not the engineers. In all of the cases related to the early Ranger based SUVs the engineers really wanted to do it right, but the bean counters wouldn’t let them. Even if you weren’t directly involved with these vehicle programs I bet you still have some stories about engineers frustration with that.
Hi Tom,

I started at Ford in 1973 on Jan 3. So I was involved with both Bronco II and Explorer. I am not under gag order on either. The Explorer was never at risk of stability even which the old twin I beam. It was criticized for harsh ride, which is suspension tuning more that suspension. It was Marketing that was still selling Ford Tough meant Twin I beam...We did finally get SLA with the UPN105 program. The thing with the Firestone Tire/Explorer rollovers had many facets...way too much to detail here but there is one that I wish to point out...There is a Ford test called Rim Rolloff. This is the the tire pressure where the tire rolls off the rim. At the time Rim Roll of on the Explorer was 24 psi. Very typical for wheel and tires...no biggie....Then Program management in order to address harsh ride complaints lowered the tire pressure on the door label to 25 psi...on psi above rim roll off.....JMO...this was a VERY POOR decision. After the fiasco and finger pointing, Ford quietly released an edict from on high that minimum tire pressure on all Ford vehicles will be 30psi...

Okay, On to the Bronco II.... Yes many engineers felt the vehicle was a bit unstable and there was quite a bit of vehicle dynamics testing before and after BII was in production. We never had a testing roll over though so it was put into production...then when the buff magazines etc started criticizing its stability, there was a push to improve the stability but the management resisted as it would be perceived that the vehicles on the road were inferior and the lawyers would descend on us. So we released a very heavy skid plate for all BII which did help a bit and revised the suspension settings but never did a deep dive wholesale revamp that some wanted... I think this hurt Ford more than if they had redone the suspension. I had opportunity to throw a few BIIs around on the handling track, being a racecar driver, and never had a limit handling problem with BII...but I was not doing emergency handling work...just limit handling... I was not part of the Vehicle Dynamics area, so my work was taken with a grain of salt so to speak...

Okay...a bit long winded here...

Likely leaves more questions than answered but Yeah...I was around for the birth of the Ranger in 1982½....

Best,
Phil
 

DHH

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This thread should be stickied
I logged in just to back you up on this one.
Probably the most informative and entertaining threads here.

KJRR, thank you for compiling the stories!
 

Ranger_Pawl

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Okay...a bit long winded here...
As far as I'm concerned, Phil's posts are NEVER long winded. Having worked (and still working) in the same environment (admittedly as a very miniscule peon) his back stories interest me greatly. I read them all, and envision Phil as one of those guys that has exceptional knowledge, but shares it in a way that doesn't make you feel stupid. I run into guys like that now and then. They are a joy to be around and work with. I imagine Phil was one of those guys. We are REALLY luck to have his input here.

1647014545596.png
 

DakotaGuy

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Hi Tom,

I started at Ford in 1973 on Jan 3. So I was involved with both Bronco II and Explorer. I am not under gag order on either. The Explorer was never at risk of stability even which the old twin I beam. It was criticized for harsh ride, which is suspension tuning more that suspension. It was Marketing that was still selling Ford Tough meant Twin I beam...We did finally get SLA with the UPN105 program. The thing with the Firestone Tire/Explorer rollovers had many facets...way too much to detail here but there is one that I wish to point out...There is a Ford test called Rim Rolloff. This is the the tire pressure where the tire rolls off the rim. At the time Rim Roll of on the Explorer was 24 psi. Very typical for wheel and tires...no biggie....Then Program management in order to address harsh ride complaints lowered the tire pressure on the door label to 25 psi...on psi above rim roll off.....JMO...this was a VERY POOR decision. After the fiasco and finger pointing, Ford quietly released an edict from on high that minimum tire pressure on all Ford vehicles will be 30psi...

Okay, On to the Bronco II.... Yes many engineers felt the vehicle was a bit unstable and there was quite a bit of vehicle dynamics testing before and after BII was in production. We never had a testing roll over though so it was put into production...then when the buff magazines etc started criticizing its stability, there was a push to improve the stability but the management resisted as it would be perceived that the vehicles on the road were inferior and the lawyers would descend on us. So we released a very heavy skid plate for all BII which did help a bit and revised the suspension settings but never did a deep dive wholesale revamp that some wanted... I think this hurt Ford more than if they had redone the suspension. I had opportunity to throw a few BIIs around on the handling track, being a racecar driver, and never had a limit handling problem with BII...but I was not doing emergency handling work...just limit handling... I was not part of the Vehicle Dynamics area, so my work was taken with a grain of salt so to speak...

Okay...a bit long winded here...

Likely leaves more questions than answered but Yeah...I was around for the birth of the Ranger in 1982½....

Best,
Phil
Thanks for another story Phil! I wasn't even alive in 1973 and would have only been 6 in 1982 so those stories are very interesting and fascinating to me because vehicles built off that platform... It was called Project Yuma inside Ford correct? were everywhere. I also remember my father buying a Thunderbird in the late 80s and my mom wanted a Bronco II instead and my dad was like those things flip too easy! Of course, that platform went on to be re-engineered and be developed into the 1st and 2nd gen Explorers.

The first brand new vehicle I ever owned coming home from the war in Iraq was a 3rd gen 2005 Explorer. Black and gray XLT with the FX4 style wheels and the moon and tunes package which was a moonroof, a nicer stereo and leather/vinyl seats (but they weren't heated which sucked in the winter). It also had the Flex Fuel 4.0 V6 in it and I ran some E85 because it was cheap when gas was high in the late '00s. The biggest complaint I ever had with that Explorer was it was one of the first with a drive by wire system at least for Ford trucks. Man did that thing have a delay when you kicked down. Kick down.... Wait wait... Off we go!

Anyhow that is a story of my own. I've owned several new Fords between that 2005 Explorer and my 2019 Ranger, but that Explorer and my Ranger are by far my favorites. Hopefully I will soon get my 2022 Tremor and I think I will also really like it.
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