Ford's US Production Takes Another Hit After New York Factory Fire

Ford’s F-150 production was in jeopardy earlier this month after a fire at a key supplier’s facility in New York. That supplier, Novelis, produces nearly half of all the aluminum used by US automakers. Now, fresh details show the ripple effects are growing. Ford has reportedly decided to conserve what aluminum it can get and focus on its most profitable products – the F-Series trucks.

While that strategy keeps its most important vehicles rolling, it means others aren’t as lucky. The company announced it has again halted production of the all-electric F-150 Lightning, this time due to restricted access to aluminum. That shutdown began on October 13, and insiders expect it could stretch for several weeks.

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Ford Pauses Large SUV Production Amid Shortage

According to the Detroit Free Press, Ford has now extended the pause to its full-size SUVs, the Expedition and Lincoln Navigator, both of which use aluminum bodies. Built alongside Super Duty pickups in Louisville, Kentucky, the two SUVs will be off the line for at least a week, possibly two. For now, Super Duty production continues unaffected, though Ford is clearly managing aluminum allocation closely.

Analysts estimate Ford could lose anywhere between $500 million and $1 billion due to the ongoing shortage. Aluminum prices are rising amid tariffs and supply constraints, and even when the damaged Novelis plant returns to partial operation – possibly in early 2026 – the shortage could persist for months. Ford’s F-Series trucks remain the priority, given their 20 percent profit margins and annual sales volume of roughly 600,000 units.

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Expect Delays on Certain Models

For customers, the impact may take longer to show. Inventory levels of the Expedition and Navigator were already down by more than 30 percent last month. That means if you’ve recently ordered one, delivery might take longer, or dealers could start marking up prices once existing stocks tighten.

Ford says it’s working with Novelis and other suppliers to manage the situation, but it’s unclear how long it can maintain steady output without a significant production hit. With aluminum supplies unlikely to normalize until next year, Ford’s focus on its bread-and-butter seems like the only practical move for now.

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