Manufacturing

Passat out, ID.4 in for U.S. Volkswagen customers, plant workers

The ID.4 will ramp up production as the U.S. says goodbye to the Passat.

Photo courtesy of Volkswagen AG

The Volkswagen Passat will end its run in 2023 at VW's U.S. manufacturing base in Chattanooga, Tennessee. But don't worry, Volkswagen has plans for what is next. In fact, they've already announced the products; they're just now getting around to specifying a timeline.

Currently, the Volkswagen Chattanooga Assembly Plant is producing the Passat alongside the Volkswagen Atlas and Atlas Sport. earlier this year, the plant celebrated the 1 millionth vehicle to roll off its assembly line - Aurora Red Metallic 2020 Volkswagen Passat R-Line.

Before the Chattanooga plant opened, Volkswagen hadn't made a vehicle in the U.S. in 22 years following the closing of the Westmoreland facility in Pennsylvania.

1977 Volkswagen Dasher and 2020 Volkswagen Passat The Dasher was the predecessor to the modern Passat. Photo courtesy of Volkswagen AG

The Passat got its start as a vehicle designed specifically for the North American market. Ground was broken on the Tennessee plant in 2009 and in 2011 it began producing the cars. It currently employees approximately 3,800 people. In the last nine years, the plant has produced more than 700,000 Passats and 100,000 Atlas SUVs. The new 2020 Atlas Cross Sport and the refreshed 2021 Atlas recently began production.

Volkswagen has announced that the plant will be the company's North American base for manufacturing electric vehicles including the ID.4, representing an approximately $800 million investment, starting in 2022. The expansion to enable U.S. production of long-range EVs began in November 2019.

The expansion includes a new Engineering and Planning Center (EPC) at the plant that will feature a unique, state-of-the-art high-voltage laboratory that is designed to develop and test electric vehicle cells and battery packs. These cells and packs are slated to be assembled in the U.S. before being inserted into vehicles.

Production of the ID.4 will ramp up starting 2022. It will reach full capacity by 2023, then the Passat will be shown the door. Before the U.S. production begins, Volkswagen will exclusively produce the ID.4 at its Zwickau plant in Germany.

2022 Volkswagen ID.4 The Volkswagen ID.4 will be made in the U.S. starting in 2022.Photo courtesy of Volkswagen AG

Though the Passat is leaving the U.S. market, it will continue as a vehicle for international sale. Development of the ninth-generation version of the model is currently underway.

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The 2021 Nissan Rogue is made from recycled aluminum.

Photo courtesy of Nissan North America

While General Motors is busy readying its Spring Hill, Tennessee plant to run strictly on solar power, Nissan is making its Rogue out of recycled metals just down the street. The 2021 Nissan Rogue is the company's first global model built using a closed-loop recycling system for aluminum parts.

Using a closed-loop recycling system has several benefits. It saves 90 percent of the energy that would normally be used to create the parts that are now made of recycled parts. This type of system also helps reduce carbon dioxide emissions compared to the process of making products out of raw materials.

2021 Nissan Rogue The rear doors, which are stamped from aluminum alloy, open wide on the 2021 Rogue. Photo courtesy of Nissan North America

The process starts when scrap metal is shredded and collected through a pneumatic system. Nissan then separates the different grades of aluminum in order to ensure that the high-quality scrap is collected and sent to suppliers according to which parts they supply. Different grades of material are used to make different parts of the vehicle.

The scrap is then made into sheets of aluminum, which is delivered in rolls to Nissan where it is transformed into parts for the Rogue. The hood and doors of the 2021 Rogue are stamped from the aluminum alloy.

Aluminum, which is lighter than steel, is used to reduce vehicle weight, which helps to improve fuel efficiency and power performance of the vehicle.

Nissan redesigned the Rogue for the 2021 model year. It is more powerful and spacious than its predecessor. The Rogue is also chocked full of family-friendly features and fresh technology including a new high-tech driver information screen.

Nissan builds the 2021 Rogue in Kyushu, Japan, and Smyrna, Tennessee. As part of the recycling process, Nissan has collaborated with Kobe Steel, Ltd. and UACJ Corp. in Japan, and with Arconic Corporation and Novelis Inc. in the U.S.

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The Ford Motor Company will recall about 3 million vehicles as part of the Takata airbag recall.

Photo by Matthew Horwood/Getty Images

Following the denial of a 2017 petition to the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), Ford Motor Company has announced a recall of 3 million vehicles, a move that will cost the company an estimated $610 million, according to internal estimates.

The petition is part of the larger Takata airbag recall and specifically involves the defect of phase-stabilized ammonium nitrate in the driver-side air bag inflators that Takata manufactured with a calcium sulfate desiccant. Ford wasn't the only recipient of the defective inflators. Mazda also utilized the parts.

The list of impacted Ford vehicles ranges from the 2006 to 2012 model years. They include Ford Ranger (2007-2011), Fusion (2006-2012), Edge (2007-2010), Lincoln MKZ/Zephyr (2006-2012), MKX (2007-2010), and Mercury Milan (2006-2011). Approximately 2.7 million of those vehicles are in the U.S. and 300,000 are in Canada.

Mazda is also part of the recall, with 5,848 vehicles effected by the inflator issue. Those models are 2007-2009 B-Series pickup trucks, which were built on the same platform using the same air bag inflators as the 2007-2011 Ford Ranger.

Late last year, the NHTSA ordered General Motors to recall 7 million trucks and SUVs after a four-year back-and-forth battle over whether or not the Takata air bag recall was absolutely necessary for GM products. The models recalled as part of this action are "GMT900" models that contain "SPI YP" and "PSPI-L YD" inflator variants. The GMT900 is a General Motors-specific platform that underpins a number of light- and heavy-duty pickup trucks and SUVs including: Chevrolet Silverado 1500, GMC Sierra 1500, Chevrolet Silverado 2500/3500, GMC Sierra 2500/3500, Chevrolet Tahoe, Chevrolet Suburban, Chevrolet Avalanche, GMC Yukon, GMC Yukon XL, Cadillac Escalade, Cadillac Escalade ESV, and Cadillac Escalade EXT. The petition involves approximately 5.9 million model year 2007–2014 vehicles.

2014 Chevrolet Suburban The 2014 Chevrolet Suburban is one of the models NHTSA recently ruled needed to be recalled. Photo courtesy of Chevrolet

In early 2020, 10 million vehicles were recalled after having their original equipment replaced with new versions of the same thing with the same design and chemistry rather than newly designed parts.

The Takata airbag recalls are part of the largest automotive recall in U.S. history. It involves more than 67 million vehicles to date.

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