Dearborn vs Kansas City Truck Assembly
Junior Member
Joined: May 2010
Posts: 1
Likes: 0
My FX4 was built at KC, and it was built on a Friday (the 13th even) and I'm very pleased with fit/finish. The "Late Friday" build defect is a little bit of a myth. The assembly process is so automated now that it takes much of the "skill" out of the work. There are location features and positive engagement mechanisms on all of the critical components, and most of the minor ones. That being said, although robots are extremely repeatable, it's still humans that have to program them!
I've spent time in both of these plants working on their robots, and they're pretty similar. However, I didn't spend too much time on the half ton line in KC, I was mostly on the SuperDuty lines. I will say the folks were a little less grumpy in KC
I've spent time in both of these plants working on their robots, and they're pretty similar. However, I didn't spend too much time on the half ton line in KC, I was mostly on the SuperDuty lines. I will say the folks were a little less grumpy in KC
huh thats weird u smell like lie i work at KCAP and we dont have superduty lines?!
Senior Member
Joined: Mar 2010
Posts: 464
Likes: 0
From: Roanoke, Texas
Interesting thread. I've had two 2010 F-150s and I have noticed some differences. The XLT was an early build (7/09) and my Lariat was built in 2/10. The Lariat seems to have a few more noises, but it also has more things inside to make noise. Both have been awesome trucks.
Senior Member
Joined: Dec 2007
Posts: 379
Likes: 0
From: Raleigh, NC
My 2007 F150 Lariat 4x4 Supercab was built in Dearborn and I didn't have a single problem. I was actually disappointed when I saw that my "perfect" truck, 2010 F-150 Lariat Screw 4x4 was built in KC. Both trucks honestly have great fitment and no problems. Going forward I wouldn't have a problem buying a truck assembled at either plant. I expect everyone to have a preference but after owning one from both I can honestly say I've been pleased across the board.
Member
Joined: Jan 2008
Posts: 98
Likes: 0
My 2010 platinum has many of the issues you noticed. I feel like the fit and finish is lacking in comparison with my 04 and 06. The biggest disappointment is looking down the side of the truck you can see rippled sheet metal. The other bothersome issue is the cab/bed misalignment. The glossy red candy paint doesn't help these issues. I almost wonder if one of the weight saving measures was thinner sheet metal?
However, the interior fit/finish is very good.
However, the interior fit/finish is very good.
Technical Article Contributor
Joined: Aug 2006
Posts: 7,862
Likes: 0
From: Northern California
Mine was built at the Kentucky plant mid 03, one of the first 04+ off the line. The best part about that is that I don't have those stupid molex plugs so running wires into the doors is painless. 
Junior Member
Joined: Feb 2016
Posts: 1
Likes: 0
Kansas City vs Dearborn Truck Plant.
In August of 2015, I purchased a brand new 2015 Ford F150 XLT 4x4 with the 3.5 litre V6. The truck was made at the Kansas City Plant. Within the first two weeks I had to have the front 1/2 shaft replaced because there was a constant knocking noise every-time I was turning. No to long after, I had to have the whole instrument cluster replaced. Was was happening was the driver assist digital display was showing 90 km/hr and my GPS was showing the same but the needle was showing 60 km/hr. A 30 km/hr difference. So I talked to my salesperson about what is going on after only having the truck for 5 months now and I wanted to see what he can do. What he did do was, he found the same identical truck ( brand new, color and all ) at another dealership and just did a clean swap for the other one at no cost to me. The only difference was this one came with running boards and this one was made at the Dearborn Truck Plant. Even though they are both identical trucks, the one from Dearborn feels so much tighter and better compared to the Kansas City Truck. After reading on Ford's website, the Kansas City Plant just started producing trucks so maybe they have some glitches to work out at their plant. All I can say is the produced at the Dearborn Plant feels and performs so much better then the one that was produced at the Kansas City Plant.
Senior Member
Joined: Oct 2011
Posts: 876
Likes: 14
Same here (2010 FX-4).
I can't say that I've noticed any obvious quality problems with any of the 2009+ F150s that I have looked at. (Other than the poorly designed rear window defroster and a couple of other WELL KNOWN problems.)
YMMV.
