How rigorous do automakers test their vehicles? (F150, vehicle, green light)

[sdlife619]

I have always wondered about this kind of stuff just because it seams sometimes that certain parts in newer cars seem like they simply won’t last 10 years. Or the way the car drives and smooth out bumps. It’s like the R&D testing teams have been eliminated because are road test even done anymore on crumbling pavement from certain auto manufacturers?

Do automakers test for extremely harsh situations like they used to?

I’m sure most of them have some sort of quality control check before they leave the factory or make sure there are no squeaks or rattles, but it’s crazy to me how something so small and common is missed by engineers and the factory itself.

For instance as much I love my 17 impala, I’ve noticed lately that door locks rattle inside the door panel while driving on rough pavement. It’s mostly the drivers side that makes a small rattle sound but as I check all the door locks, they all have this loose feeling like some of the old school cars in past had.

My first thought was, how in the heck didn’t anyone from the factory hear this or bothered to notice the loose locks before giving the green light for production? My other thought was, “why in the flying F is GM still using exposed locks in the first place!?” The entire car is quiet and rattle/squeak free and the only thing that makes any noise is a stupid lock!

Weather stripping and rubber window trim all seem extremely cheap and flimsy these days as well. Lots of little plastic parts like knobs and button related items might not hold up in 10 years.

This goes for paint quality, plastic door handles, undercarriage components, door hinges that keep getting smaller and less durable, etc.


Also what is up with automakers giving these “first drive” events for the media only in places where the environment is well controlled. The automakers make sure the streets are perfectly smooth, the sun is shining bright and it’s usually in a rural area so the media tester can focus on the car itself rather what is going on around him.

How about they take those cars out in drive them in real world conditions, on real urban streets that have potholes/cracks, with traffic, and let’s see how their cars are rated and judged then.

[Coldjensens]

They test test cars. They do not test each car off the line.

The door rattle may have been something they expected to happen. In that case testing would not change anything. If they are not supposed to rattle, something is wrong and you have a warranty claim. If they are supposed to rattle, then testing would have revealed them rattling and it would be considered just fine. A certain amount of noise is considered tolerable in an car.

Some things seem cheaper but are actually more sturdy due to advancements in material technology. Other things are just cheap and flimsy. One of the main goals of design these days is meeting government standards and that means make everything thinner and lighter. If stuff breaks down the road - well it is better than designing a car that you will not be allowed to sell. Besides, things breaking down the road is some other department's problem. Plus you can always blame the factory.

They do test drive new models on horrible roads. I see them out around the Detroit metro regularly and we have as bad of roads as anywhere. Usually the media testers (like car and driver) are given a car to test and they drive it where they want to. The regular media like newscasters do not test cars. They have no expertise. However it a MFG allowed them to test drive a new model, it woudl undoubtedly be on smooth roads with sunshine and ponies and butterflies along the way. Newscasters are not known for their intellect. With them you can just distract them with a shiny thing and they will say the car was perfect. Car and Driver and the like, less so.

Paint is better than it has ever been. However it is correct all components are getting smaller and more and more plastic. Gotta meet those standards ya know.

Metallurgy is getting worse because we no longer make much steel in the US and the Chinese metallurgy has been terrible by comparison for a century or more. (Before cars, they made clocks made with terrible quality metals (brass).


As with many things in our society technology improves things and a combination of cost reduction and government regulations cause continual reduction in material quality. The question is which one gets ahead of the other.

So, for example, a plastic gear or hinge is less sturdy than a metal one, until materials technology comes up with a plastic that is more durable than metal. They still use plastic gears to reduce mass, weight, cost - but they do not last. Someday they will last longer than metal.

[unit731]

From reading the original post.

Short answer.
Go trade the car in and get one that you like. Appears as if you do not like the car.

But if you don't wish to do this then take back to dealer under warranty. And KEEP all receipts for warranty work.

All manufactures send out a survey after buying a new car. Did you get the survey yet?

[headingtoDenver]

I'm not sure if you are painting a broad brush due to your experience with your Impala, but I believe new cars are more reliable than ever. They last longer than ever before and I believe quality is much higher. As stated by Coldjensens, not every car that comes off the lot goes through a rigorous testing regime due to the shear volume of vehicles being produces, but manufacturers do indeed test their lineup. As for the plastics and such, they do this to help keep costs down along with weight reduction to meet new industry standards. Now, if GM were to make your Impala with parts which will definitely last 100 years, would you be willing to pay double or triple the price?

[Stonepa]

Not sure what you mean by 'exposed locks' but electronic locks only work well if you have battery power. And no interference. And a key fob that works. And a car of a high enough trim level to provide for electronic locks. The only car I have spent time in that has fully electronic locks is a Tesla Model S. Even my Bentley and new Ferrari FF have backup mechanical key lock.

[Crashj007]

Sounds like you underbought your car. Youseem to be looking for higher quality than a Chevy; next time buy a Cadillac. That has more sound deadening materials and lockwashers.

[easy62]

When I. Lived in Milford Michigan I seen many GM cars all Camouflage running around town, their proving grounds are their and they have every imaginable type of road conditions. Also the automakers teir 1 suppliers also. Put their parts through rigid testing also. I’ve see emergency brake lines. Go through a years worth of usage in a month with saltwater being sprayed on them 24/7 while another machine operated a lever like the emergency brake one in your car. All these tier 1 suppliers have their own engineers also. I’ve also seen brand new automobile’s. Being taken apart to see how a certain parts are hold up. Lots os other suppliers out their that you would never recognize their names like small shops that make fasteners for inside door pannles, or bolts to hold hood hinges on and so on it’s not always the. Big suppliers like Johnson Controls, or TRW, or Bosch. There are so many suppliers out their that make parts for the automotive industry.

[TrapperL]

All pre-production cars are road tested, many for millions of miles. Some are tested by independent shops that run the wheels off of them with target areas like brakes, shocks, wet handling, high speed, stop and go, etc. We have 2 companies locally that do just that and an R&D center that test the individual components of the engines and transmissions. That part is something to see but rarely is it open to the public. The tests are for wear of individual components like the cams, followers, heads, turbos, bearings, lubrication system, etc. Once the vehicle comes out of pre-production and assigned a build number, during the build process, random units are pulled for the line and tested for fit and finish. They will also pull units from the end of the line that are ready for delivery to the dealer and tear them apart and all parts of it looked at. Then the vehicle is rebuilt like a custom vehicle by a team of specialist. The F150 I'm driving is one of those units with the inspection and audit tag still on it. That your door lock rattles is more of a defective part that most likely is not to specs but works. The plastic is what you're buying when buying a "cheap" car. The car would cost a lot more if it was all metal. If the cheap bothers you, next time try a higher quality brand. But since recycling is now the politically correct crapola, even the higher end vehicles are using more and more plastic. It also a lot lighter in weight and the car makers are against the wall with CAFE requirements and still give you enough power to get out of the way.

[octo]

Originally Posted by Coldjensens

However it is correct all components are getting smaller and more and more plastic. Gotta meet those standards ya know.

Uh. It's all about cost, not your imagined agenda. If you buy a cheap Impala you get what you pay for.

There's nothing cheap and flimsy in my 2017 BMW and my 2018 Porsche.

[unit731]

Originally Posted by octo

Uh.
There's nothing cheap and flimsy in my 2017 BMW and my 2018 Porsche.

Absolutely.

Until the repair bills come in. Then quite expensive.

BMW story Number 1

Neighbor purchased new BMW 4 door sedan for daughter.
Issue 1 Right headlight goes dead.
Repaired at BMW dealership.
One month later.
Issue 2 Right headlight goes dead.
Repaired at BMW dealership.
One month later.
Issue 3 Right headlight goes dead.
Repaired at BMW dealership.
One month later.
Issue 4 Right headlight goes dead.
Repaired at BMW dealership.
All times are +/-.

At this point neighbor is about to file a claim on Lemon Law.
BMW dealership finally calls in German specialist.
Replaced CPU/main computer on car.

BMW story Number 2

Lady purchased top of line 4 door sedan.
Lady has two homes. One East Coast and one in Southwest.
Has a Ford Explorer at Summer home East Coast.
Has BMW in SW.
Lives Winters in SW. Summers East Coast.
A few years of leaving BMW in Southwest in Summer.
Gets back to SW and dead battery.
Calls the BMW dealership where she purchased BMW.
BMW dealership is too busy to come and replace battery. Lady is prepared to pay for battery and service call.
BMW dealership advises lady to telephone one of the independent contractors approved by BMW dealer.
They come put battery in but cannot start car.
Taken - towed to contractor shop. Can't get BMW started with new approved battery.
Towed to BMW dealership.
The whole instrument panel lights do not work. Lady advised that she should not have let the BMW contractor to put a battery in car. As only the BMW dealership can do this correctly.
Lady states that it was the BMW dealership that told her to get the BMW authorized shop to put battery in.
Out of warranty. Lady must pay for new instrument cluster, towing, and other parts charges.

This lady will never purchase another BMW. These two BMW stories are flukes, right?

Lady is going to purchase a new Ford Explorer for the home in SW as no issues with the Ford.