"It's a commuter's nightmare." That's the way Mary Ann Wright describes the extreme driving test that begins today for the all-new Ford Escape Hybrid. Starting in midtown Manhattan during the morning rush-hour, the Escape Hybrid will be driven up, down and across the island over some of America's most congested streets and avenues. Chief engineer for the Ford Escape Hybrid, Wright won't stop the test until the small SUV's gas tank is completely dry. That may take 36 hours or more of non-stop driving.
"We've designed ‘Manhattan on a Tank of Gas' to see how many miles an Escape Hybrid can be driven on a single tank of gas in some of the worst conditions for fuel efficiency most drivers would ever face," says Wright.
Ford Escape Hybrid is the world's cleanest and most fuel-efficient sport utility. Available at the end of this summer, it combines the fuel economy and emissions benefits of a "full" hybrid with the go-anywhere capability, toughness and spaciousness of the Ford Escape, America's favorite small SUV. Escape Hybrid is the first hybrid electric vehicle that can comfortably accommodate five adults and their gear. "No-compromise utility separates Escape Hybrid from other ‘green' vehicles," Wright says.
"Escape Hybrid can provide an economical solution to a problem commuters face every day – bumper-to-bumper gridlock that can bleed a normal car's fuel tank dry," she says. "At the same time, Ford Escape Hybrid is a practical and livable environmental solution to help address air quality problems in our cities, as well as the global warming issue."
Making the epic Manhattan drive particularly impressive is the fact that the Escape Hybrid's gas tank holds just 15 gallons of fuel.
"Other vehicles might start out with more fuel but they will go through it a lot more quickly," Wright says.
An SUV that Excels in the City
The 2005 Ford Escape Hybrid is expected to be rated at between 35-40 mpg on the EPA city cycle – an improvement of at least 75 percent over the EPA city fuel economy rating of 20 mpg for the conventional V-6-powered Ford Escape, the best-selling small SUV in America. Escape Hybrid's fuel-efficient four-cylinder engine combines with an electric drive system to deliver acceleration performance similar to that of the V-6 Escape.
While a conventionally powered vehicle burns fuel and creates emissions while idling at a red light or bogged down in stopped traffic, the Escape Hybrid's engine shuts down at rest to conserve fuel. When the light turns green or traffic moves forward, Escape Hybrid's 70-kilowatt traction motor generator can launch the vehicle on clean electric power. When needed, the generator can smoothly start the gasoline engine in less than 400 milliseconds, without the increased emissions produced in starting up a conventional engine. Escape Hybrid also conserves energy in stop-and-go driving by reclaiming energy during braking to charge its hybrid storage battery to be used later during acceleration.
"Near Zero" Tailpipe Emissions
Escape Hybrid is an extremely clean vehicle to operate, producing 97 percent less hydrocarbon and oxides of nitrogen emissions than vehicles that meet today's nationwide Tier I emissions standard. That's clean enough to qualify the 2005 Escape Hybrid for the stringent Advanced Technology Partial Zero Emissions Vehicle (AT-PZEV) standards.
Escape Hybrid achieves the AT-PZEV standards by combining an efficient powertrain with an exhaust catalyst system that is very effective at lowering smog-forming emissions.
Indeed, the Ford Escape Hybrid is as environmentally friendly as a vehicle that runs solely on electric power. That's because a battery-electric vehicle needs to be plugged in to be recharged, and that electricity must be generated by a power plant, creating some smog-forming emissions. The Escape Hybrid, on the other hand, never needs to be plugged in. Its battery is continually recharged by an ingenious system that reclaims energy when the brakes are applied.
The Escape Hybrid also produces as little as half the amount of carbon dioxide (CO 2 ) – a harmless gas in terms of ground-level air quality but a primary "greenhouse gas" when it drifts into the Earth's upper atmosphere. An accumulation of greenhouse gases in the atmosphere is widely believed to be producing a global warming effect. CO 2 and water vapor are produced in the clean combustion of any type of carbon-based fuel, so the only effective way to reduce a vehicle's CO 2 emissions is to reduce the amount of fuel consumed. Fuel-efficient hybrid-electric vehicles can substantially reduce CO 2 emissions.
Ford Motor Company and other automakers are working on long-term research projects to someday make practical hydrogen-powered vehicles that will not produce any greenhouse emissions. In addition to the Escape Hybrid, PZEV Focus and Focus Diesel being produced today, Ford has developed a Focus hydrogen internal combustion engine (H 2 ICE), a hydrogen hybrid research vehicle (H 2 RV) and a Focus Fuel Cell Vehicle (FCV) that is operating in demonstration fleets in the U.S. and Canada. Ford is the only automaker with such a full-range of production vehicles and research efforts intended to move society to a hydrogen-powered future.
Engine Dressing
Doug Gaffka's – design director, Ford Performance Group – design inspiration for the Mustang GT-R was simple: Flex the 2005 Mustang shell to wrap the engine and retain 85 percent of the production car's solid structure.
"We decided that when a car as good as the 2005 Mustang comes along, we don't need to look much further for a pure race car," he says, noting that the Mustang's shell would be dressing for the engine and roll cage.
The carbon fiber hood instantly communicates the car's performance – its large engine bulge and unfinished surface harken back to the famous yellow, black-hooded Mustangs..
The front end is a further evolution of the Mustang GT coupe and convertible concepts that stole the 2003 North American International Auto Show and foreshadowed the design of the 2005 Mustang. The Mustang GT-R features the classic pony in the grille, surrounded by modern materials like carbon fiber as well as advanced aerodynamic treatments like ground-hugging front and side splitters.
Accentuated by huge front fender flares that accommodate the racing suspension, the sides of the Mustang GT-R have 20-inch wheels, racing slicks and substantial air scoops. The equally large rear fenders house tires that are an inch wider. Considering how quickly 18- and 19-inch tires became standard racing ware in recent years, these tires are a realistic forecast of the next evolution in racing rubber. Dual stainless steel exhaust tips -- jutting out of the rear body panel just above the rocker panel on both sides in front of the tires – add an intimidating look to the rear of the car.
The classic Mustang rear quarter windows are blocked out to accommodate the fuel delivery "dry-brake" system on the driver's side. The doors are fully functional as required by many of the possible racing classes.
The prominent GT-R logo is placed above the front fender and is flanked by the honorary "Mustang" and "40 th Anniversary" words. This logo is repeated on the rear.
Probably the most striking design element, the prominent composite rear spoiler meets several road racing sanctioning body rules.
The rear fascia, like the front, is a further expression of the GT concept design, with a wider taillamp execution. Endurance racers will instantly recognize the differential cooler mounted with an aluminum grille screen between the taillamps.
Inside, the instrument panel preserves the dramatic styling of the 2005 Mustang in a carbon fiber application for racing. In anticipation of another trend, designers chose a Formula One-style steering wheel with most vehicle controls and gauges integrated, including the tachometer, gear selections, telemetry and warning signals. Only the oil pressure and water temperature gauges are located on the instrument panel.
"Most racers cobble together interiors," says Gaffka. "The Formula One-style steering wheel significantly reduces dash gauges to help preserve Mustang's powerful instrument panel, which is the next evolution of our interior design leadership."
The passenger side houses seat mount tracks for a second seat, if needed, for would-be thrill seekers seeking first-hand Mustang GT-R's performance experience. The chrome-moly roll cage is attached to all significant points in the body structure, adding significant rigidity to an already stiff body.
The Mustang GT-R's body retains 85 percent of the production car's body components that were stiffened by 30 percent as part of the Mustang's first full makeover ever. The only modifications include rear-mounted battery pods and a fuel cell relocated to the rear trunk.
Built at Saleen Special Vehicles in Troy, Mich., the car was developed by the same members of the Ford GT "Dream Team" who are building sub-assemblies and painting body panels for Ford's first supercar.
The "Five Liter" Is Back
The foundation for the Mustang GT-R's race-prepared 440-horsepower engine is the new 5.0-liter "Cammer" crate engine from Ford Racing Performance Parts. The engine is rooted in the MOD 4.6-liter four-valve V-8 engine family. However, the motor's flanged cylinder liners help provide 94mm (instead of 90.2mm) cylinder bores, creating a full 5.0 liters of piston displacement.
And while the motor employs the SVT Mustang Cobra's forged crankshaft with six-bolt mains and Manley "H-Beam" connecting rods for superior strength, the high-strength Ford Racing block features design reinforcements and a revised material for added strength and high-output durability. The block is specially reinforced in the crankcase web areas for high torque loads.
Other key differences include forged pistons, an 11.0:1 compression ratio, ported heads, higher-lift cams and beehive-shaped valve springs. The crate engine also features higher-flow fuel injectors and a magnesium, variable-geometry intake manifold.
The 5.0-liter "Cammer" engine comes with a custom oil pan and features custom-fabricated Tri-Y headers and crossover.
Helping put the power to the ground is the Ford Racing-supplied TTC T-56 six-speed transmission linked to the engine through a heavy-duty clutch and flywheel assembly. Power exits the transmission through a custom metal matrix composite aluminum driveshaft into a race-specification differential with a 4.56:1 final drive ratio.
The "Cammer" was introduced at the Specialty Equipment Manufacturers Association show in 2002. The engine in the GT-R is identical to the crate engine, with the exception of camshaft timing, which was modified to produce more high-end horsepower for track use.
Proven Race Chassis
The Mustang GT-R benefits from the 2005 Mustang's race-inspired chassis, developed and tuned by engineers with Ford Racing engineering experience or a passion for weekend track time. The Mustang's race-bred suspensions, near 50-50 weight distribution and ultra-stiff body structure, are just the beginning of Mustang GT-R's credentials.
"The GT-R is the ultimate expression of the Mustang platform," says Hau Thai-Tang, 2005 Mustang chief nameplate engineer. "Mustang spans more of the market than almost any other car – from an under-$20,000 V-6 to a race-ready car in the $40,000 range. The Mustang GT-R shows how we can expand that unmatched reach with the all-new platform."
Track time – at drag strips and on road courses – was a critical part of the 2005 Mustang's development, as chassis engineers pushed prototypes to the limit in search of the perfect power-and-handling blend.
"We spent countless hours refining this car on development drives and at the track," says Mark Rushbrook, 2005 Mustang vehicle development manager. "The car has been to the Nelson Ledges road course in Ohio several times for 24-hour runs and has spent months on Ford's straightaways and handling courses at our proving grounds in Arizona, Michigan and Florida."
Soon after the 2005 Mustang's world reveal in January, race engineers quickly began building on its solid foundation. The Mustang GT-R concept's chassis was fully stripped down to the body shell to receive custom reinforcement and structural improvements for driver safety on the racetrack. A roll cage was added, along with a Sparco-brand racing seat with a five-point safety harness.
The production suspension geometry is retained, but key parts were replaced to reduce weight or provide additional strength for the rigors of racing. Suspension pieces, including the K-member, are made of lightweight chrome-moly tubing. The race-proven dampers are coil-over, fully adjustable units featuring remote reservoirs. A strut tower brace increases structural rigidity.
Rounding out the chassis package are huge, race-proven Brembo brakes. The front features 14.3-inch rotors with six-piston calipers; the rear has 13-inch rotors with four-piston calipers. Linking the whole package to the racetrack are 20-inch wheels and racing slicks provided by Pirelli. Tire sizes range from 275/35 in front to 305/30 in the rear. The Mustang GT-R is engineered with modern aerodynamics principles, including a massive front airflow opening and carbon-fiber belly pans that reduce underbody air turbulence.
Concept to Reality
Although the Mustang GT-R is a concept, the car was engineered to perform at racing speeds with parts currently available to weekend racers through the 2004 Ford Racing catalog. The 5.0-liter EFI "Cammer" crate engine, including the wiring harness kit, will sell for an MSRP of $14,995. The "Cammer" engine takes the guesswork out of installation projects by offering a choice of several length 5.0-liter, 4-valve modular wiring harness kits created specifically to cover the most popular engine swap configurations. What's more, harness kits – which include the powertrain control module (PCM) – provide all the necessary electrical connectors, including end terminals, a fuse box, a power distribution box, as well as switch connectors and fuel pump relays. The roll cage, rear spoiler and some chassis components are all being considered for further development.
Text and photos courtesy of Ford Motor Company
