Trashed by a Twister and Crucial to Ford, a BorgWarner Plant Struggles to Get Back on Its Feet

A South Carolina assembly plant that took major damage from a tornado back on April 13th is making headway in returning to production. It’s still a long way from normal, but the plant’s promise of “limited production” in the coming weeks should be music to the ears of Ford, which relies on the Seneca, SC facility for components for its biggest-margin vehicles.

It still isn’t known when exactly Ford plans to restart vehicle assembly in the U.S., but May 18th has been floated as a possibility. In Seneca, the tornado-toppled BorgWarner plant, builder of transfer cases for 4×4 systems, could be back in business by that point. Sort of.

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Bad News for Ford: Carolina Twister Makes Direct Hit on Automaker's Supply Chain

An outbreak of tornadoes through the Gulf states and into the Southeast early last week saw one twister shatter a sprawling BorgWarner assembly plant. Known for building all-important transfer cases for four-and all-wheel drive vehicles, the Seneca, SC facility lay in near-ruins following the direct hit, though it wasn’t known which manufacturers sourced components from the plant.

Well, it turns out one recipient of Seneca-built parts is Ford — and it uses a lot of them.

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  • Probert They already have hybrids, but these won't ever be them as they are built on the modular E-GMP skateboard.
  • Justin You guys still looking for that sportbak? I just saw one on the Facebook marketplace in Arizona
  • 28-Cars-Later I cannot remember what happens now, but there are whiteblocks in this period which develop a "tick" like sound which indicates they are toast (maybe head gasket?). Ten or so years ago I looked at an '03 or '04 S60 (I forget why) and I brought my Volvo indy along to tell me if it was worth my time - it ticked and that's when I learned this. This XC90 is probably worth about $300 as it sits, not kidding, and it will cost you conservatively $2500 for an engine swap (all the ones I see on car-part.com have north of 130K miles starting at $1,100 and that's not including freight to a shop, shop labor, other internals to do such as timing belt while engine out etc).
  • 28-Cars-Later Ford reported it lost $132,000 for each of its 10,000 electric vehicles sold in the first quarter of 2024, according to CNN. The sales were down 20 percent from the first quarter of 2023 and would “drag down earnings for the company overall.”The losses include “hundreds of millions being spent on research and development of the next generation of EVs for Ford. Those investments are years away from paying off.” [if they ever are recouped] Ford is the only major carmaker breaking out EV numbers by themselves. But other marques likely suffer similar losses. https://www.zerohedge.com/political/fords-120000-loss-vehicle-shows-california-ev-goals-are-impossible Given these facts, how did Tesla ever produce anything in volume let alone profit?
  • AZFelix Let's forego all of this dilly-dallying with autonomous cars and cut right to the chase and the only real solution.