2012 Ford Focus Electric: How It's Built On Same Assembly Line (Video)

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With the first sales of the 2012 Ford Focus Electric registered last month, Ford's battery-electric compact hatchback enters the market to compete with the Nissan Leaf and other plug-in cars.

Unlike the Leaf, though, the Focus Electric is an adaptation of a high-volume gasoline-powered car.

And Ford is proud of the fact that it's built on the same assembly line in its Wayne, Michigan, plant as every other Focus.

The line workers omit several steps and add a few others to build a Focus Electric amidst dozens of gasoline Focus models.

It starts with a different floorpan stamping, though the rest of the body shell is largely the same.

The assembly sequence installs the lithium-ion battery pack roughly between the rear wheels, adjacent to the station where gasoline tanks are installed in regular Focuses.

Similarly, the electric motor, power electronics, and orange high-voltage wiring are added in stations spread throughout the rest of the assembly process.

Watch the video for Ford's full explanation of what's new, what's left out, and how a 2012 Focus Electric is assembled.


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Comments (3)
  1. Thanks for this glimpse of the Ford Focus EV -- there are two main pieces of the battery, I take it? I can appreciate that they are saving time to retrofit the EV drivetrain in the standard Focus chassis, but it sure would be a better EV if it was a "ground up" design -- it would be a better EV! The Cg cannot be ideal -- do they change the suspension to compensate? Do they change the grill?


  2. Even though a 'ground-up' EV design would be better, i think overall this approach is better. You should be able to go into a dealership and find the car you like, then choose the drive system to go with it. Diesel? EV? Petrol? Pick! That way we get real cars, not crazy things that make people laugh.

  3. By building an adaption to the standard car, you get to know exactly how much the EV conversion is costing you. The Volt for the same price gives you an extended range engine. The LEAF for a much lower price gives you much more luggage space. Hard to find a justification to purchase the Focus EV.

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