I compared a few '09 models (Lariat, King Ranch and Platinum) and couldn't help but notice assembly differences between the two plants. While it's not a scientific approach, it's my impression the Dearborn trucks have more body panels not fitting too well and/or varying gap width between the panels. The Dearborn trucks seem to have the hood slightly recessed in with respect the front edges of the quarter panels and the creases near the bottom on passenger side doors did not align with the quarter panel or the back piece of the cabin just behind the door before the box. On the three Dearborn assembled trucks I looked at closely, this was the case. On the other hand, the Kansas City trucks appeared to have a better fit and uniform gap widths between the panels and doors.

The reason I bring this up was because of the problems I found on a new Platinum, assembled in Dearborn. The truck was located at a nearby dealer and the dealer settled for price that I thought was fair. My concerns about the fit and finish I had seen from the Dearborn plant was made to the salesman. Naturally, the salesman swore the fit and finish was impeccable, perfect, etc etc. Over the phone, the deal was conditional upon my acceptance of the truck upon a test drive. Long story short, the truck was probably a late Friday assembly (it was assembled on 1/16/09). Panels did not line up with the corresponding panels. Gaps varied along the lengths. Opened the driver's door and the rubber grommet/conduit popped out from its seat (the piece of flexible rubber covering the wires going into the door panel). The interior appeared to be assembled nicely and the truck drove very well except the transmission was performing differently than the other '09s I tested. When I backed up, there was a hard engagment of reverse that sounded like something slammed together and the truck would jerk backwards. That was the 3rd strike for me and I back out of the deal for that truck.

A new '09 KR was at the same dealer. Yes, the KR was assembled in Kansas City, the fit was typical of other trucks from that plant, better than Dearborn trucks I have seen, especially the Platinum I drove. I drove the KR home in lieu of the Platinum.

Have others found the same assemby differences between the plants?

 

My truck was born at the Dearbarn Plant, and I have no issues with fit and finish. Maybe it was made on a Tuesday or Wednesday. Is there any way to tell what day it was made?

 

Dearborn here as well, no problems at all. All panels line up perfectly, door gaps are uniform, interior is impeccable. I believe all Platinums are assembled at Dearborn, so Ford must think they are doing something right to have their flagship F150 assembled there and nowhere else.

 

My 2007 was built at the KC plant & everything is fabulous!......

 

My 2008 was built in Dearborn... I have not noticed any problems.

 

My 09 FX4 was built in Dearborn mid December. Not fit problems.
My last truck was built in Kansas City. The hood was a little off on the front. I noticed when I tried installing a bug shield and it rubbed. It was great truck non the less.
I had wanted another Kansas City built truck again, but it seemed like all the 09's that I looked at were assembled in Dearborn.

 

09 built in KC havent notice anything that looks off. Last truck was also built in KC and it looked like the drivers side doors (Scab) didnt line up properly. The rubber trim around the door looked like it was about 1/8-1/4 lower then the rear. Not a big deal, no wind noise or anything and I dont think anyone else noticed or would even notice.

 

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 think i remeber them picking the DB plant for the platinum because it was better set up to build the platinum models. I wouldnt have thought they would build their best truck they make the worst built. Cant say i have noticed any problems with fit. I been over every square inch about 3 times due to waxing and pre cleaning an cant say i noticed any issues.

 

Great replies. Perhaps it was a weird coincidence for me. I was really disappointed with the apparent defects on the Platinum but maybe it was the bad luck of the draw.

It's easy to check the build date. You can either ask the salesman to give you the information or you can flip open the gas nozzle cover. The little sicker on the inside face is the build date.

 

DearbornDerek,
What are your thoughts on this?

 

Also, you can check the vehicle information sticker in the door jam. In the upper left corner, the date is listed. (Ref. page 396 of the manual)

Another note, fit/finish issues can be the result of the quality of the stamped parts (hood, fender, door panel, etc.). Some parts are manufactured at FMC stamping plants, some parts are sourced from tier suppliers. It could be as simple as you got a hood that was produced on a day or shift when the dies or the press were acting up, or maybe something as crazy as the one slot that your hood was placed in for transport was bent 1/16" of an inch. Who knows, there are so many little variables that can have a "butterfly effect" on your finished product. Either way, good luck with everything.

 

I have had 2 F150's from the KS plant. 1999 and now the supercrew. The 1999 supercab is a great truck. The stupid heater **** (5 years) and overdrive button ring broke(6 months). Other than that - brake pads, rotors, tires, and regular fluid changes were the only maintance needed. My friends with their chevy trucks gave me endless S#$t for buying a Ford, but they were the ones in the shop getting engines and transmissions fixed. Huh? Some people never learn - they just borrow my tools.

 

KC doesn't have a SuperDuty line.

 

Sorry! I mix up KTP and KCA. I only spent a couple days at Kansas City assembly then went right over and spent 2 weeks at Kentucky Truck Plant. It was a few years ago and I was spending more time on airplanes than at home I guess the memories have blended together.