How the F-150 is being rebuilt for Europe
It is not surprising that cars sold in Europe have to comply with European laws and regulations. But did you know that the rules are so different between the US and Europe that all cars built for the US market have to be physically rebuilt before they can be registered in Europe?
Importing a car built for the US market into Europe requires extensive modifications and adaptations for the car to can pass a registration test in Europe. It's called homologation and, for the Ford F-150, work is done in a purpose-built workshop directly in the port area of German Bremerhaven, where the cars arrive by boat from the United States. With the F-150 now being sold in Europe through Ford's official dealer network, the homologation process has been reviewed and approved by Ford Europe's Special Imports unit to ensure the same quality requirements as for other Ford vehicles.
Software updated with the correct language
Perhaps the most obvious thing that needs to change is the car's software – including infotainment systems, menus and voice control, which needs to be recoded with the right language. Even the car's navigation system is taken out of the car and fitted with new software, with the right language and the right maps. This way, as a Swedish F-150 customer, you experience a vehicle that is fully customised for the European market.
Updating software on a car might sound easy but we have had to put together completely new software and develop our own methods to load it into the car, as Ford does not make this car for the European market.
Biggest changes in lighting
Software aside, the biggest changes are made to the car's lamps and lighting. In addition, we consult with the leading experts on the legislation in force in the different markets to develop safe and sustainable solutions for each country. The work is reviewed and approved by both Ford Europe and the inspection body TÜV Nord. But unfortunately it is not as simple as just making changes to the software that governs lamps behaviour. Allowed colours and lighting positions do differ, so lights and glasses must be physically replaced. New lights, such as rear fog lights, will also need to be fitted, and on the F-150 Raptor, special width marker lights will be installed.
Months of research and development behind the changes
Replacing a lamp may sound simple, but the electrical systems in a car today are incredibly complex and extensive, largely due to the almost endless array of safety features controlled by electronics and various sensors around the car.
Therefore, making changes to electrical cables can have dire consequences if you are not fully aware of what you are doing. Much of the work, in fact, involves research and development to develop methods and tools for designing the new modules that are plugged in to work properly, without disrupting or destroying functions that should remain and not affect the long-term operation of the vehicle.
If you just run a cable from the nearest mains socket to the lamp you want to install, you will most likely cause electrical faults or see the dashboard lit up with various errors because the car fails to recognise the voltages. In the worst case scenario, you can disable vital functions.
Country-specific adaptations
Some of the changes made are even different for each country even within Europe. In some markets, customers prefer to run on LPG, or liquefied petroleum gas, and the engine is being rebuilt to meet that demand. Especially in northern Europe where we have a cold and wet climate, the car's undercarriage is also treated as part of the adaptation to the European market.
Custom-built components and meticulous documentation
Last but not least, new modules and cable packages must be manufactured, qualitatively and waterproof. In Bremerhaven, the workshop has its own cable factory that customises new cable harnesses exactly to the requirements and needs of the F-150.
As an additional layer of safety and quality, the factory that homologates the F-150 uses quick disconnects for all connectors, which means the changes are fully reversible. It facilitates future troubleshooting if the car ever needs to be serviced. All parts that are replaced, added or changed are also noted in the car's component register. So when the car arrives at an authorised Ford workshop, the mechanic can immediately see how the car is built and which spare parts belong to it, whether they are original construction or homologation parts.