Dig into nearly any automobile, below the hood or within the inside, and you could find every kind of bizarre bits and items. For those who’ve purchased a less expensive mannequin, you may discover plenty of blanked-off switches or cable harnesses that go nowhere. Or, in the event you’ve purchased a contemporary Ford Bronco, you may discover a completely pretend speaker and amp — sure, dummy components virtually like film props — within the again. Isn’t that curious?
A video from BuckleUpButtercupTV provides us a fantastic have a look at this curious manufacturing choice from Ford. At the back of her Bronco, there’s a “dummy” amplifier and subwoofer residing behind a trim panel. Each are non-functional, regardless that the speaker appears like the actual deal and the amp has wires popping out of it. The trim panel even has a grille for the speaker, regardless that none of it really works!
Hunt round on-line and also you’ll discover a entire ton of Bronco homeowners who’ve discovered the identical pretend elements behind their vans. So what’s occurring? Why would Ford put pretend components within the Bronco?
Why?!
First, the background. In late 2022, the chip scarcity spawned by COVID-19 was as soon as once more inflicting havoc for Bronco manufacturing, only a few weeks in to a brand new mannequin yr. Ford discovered itself missing the components to ship the brand new customary seven-speaker audio system it had promised for some 2023 mannequin yr autos. Of these seven audio system, one was a subwoofer that lived behind the automobile. Ford moderately figured it might reduce the subwoofer with out unduly harming sound output. This allowed the automaker to maintain getting Broncos out the door. Notably, this solely affected fashions with the usual sound system, not these with the upgraded Bang and Olufsen system, which used completely different elements.
Ford didn’t cover this from prospects, in fact. As famous on the Bronco6G boards, these with energetic orders have been notified forward of time, and requested to signal an acknowledgement kind concerning the change. Clients obtained a $250 low cost to MSRP in change for the subwoofer delete. Ford additionally notified prospects that their autos wouldn’t be retrofit with the subwoofer at a later date.
Deleting the elements made sense. Ford couldn’t supply the chips it wanted to construct the amps that ran the subwoofer, and it appeared foolish to carry up manufacturing over a single speaker. Thus, it made the decision and stored the manufacturing traces buzzing. That every one is sensible. Nevertheless, the precise method Ford went about it’s moderately curious.
See, Ford didn’t simply ship the autos with the subwoofer and amp lacking. As a substitute, it nonetheless put the elements within the autos, simply utilizing dummy amps and subwoofers as an alternative. The amps are readily identifiable—they’ve the identical aluminum case as a correct unit however with a pink X on it to point the dummy standing. As coated by Finest Automobile Audio, the amplifier housing has connectors and a PCB inside, nevertheless it’s not populated with elements. In the meantime, the subwoofers lack their magnets, which might be a straightforward option to reduce prices on a sub that’s not getting used anyway.
Whereas we all know why Ford did this (provide chain constraints), we don’t know for certain why they selected this actual methodology moderately than leaving the area clean. And although Ford’s decision-making right here is just not precisely intuitive — manufacturing pretend audio system and amps prices cash — I’ve some guesses.
On a floor degree, it could certainly make extra sense to easily not set up amps and subwoofers in autos as an alternative, nonetheless, Ford clearly did this for a purpose. Analysis has did not web me an official clarification, so I’ve reached out to the automaker for remark. Within the meantime, let’s speculate—intelligently!—on why Ford went to the difficulty of putting in dummy components.
For one factor, utilizing the dummy components would forestall any disruption to Ford’s finely-tuned meeting line processes, even with a quickly altering provide chain state of affairs. The employee who’s tasked with bolting in subs and amps? She or he is gonna maintain doing the job the identical method. Certain, you can inform them to take a number of months off, or retask them, however that’s a change, and alter will get costly and fussy while you’re within the manufacturing sport. Finest to go away them be, proper? Sounds foolish, however generally the simplest path is the perfect one.
Extra importantly, although, eradicating the subwoofer and amp has penalties. Take away the subwoofer and its housing, and there’s all of a sudden nothing in between the inside trim and the outer metallic physique panel on the Bronco. That might act as a funnel for noise to enter the cabin, notably because the subwoofer is close to the rear wheel nicely. Small rock strikes and different annoying noises could possibly be way more audible with the subwoofer lacking. Equally, if the audio cable from the wiring harness had no amp to plug in to, the connector on the top would simply be rattling round contained in the trim. That might sound actually annoying! [Ed Note: I’m curious if the difference in mass between the real part and the dummy part has any NVH implications. -DT].
A populated amp PCB from a Bronco that shipped with the complete subwoofer equipment. through Enfig Automobile Stereo, YouTube screenshot
These points could possibly be solved. Ford might job an engineer with making some type of clip to carry the connector. The subwoofer could possibly be changed with a block-off panel, too. Nevertheless, these components must be designed, manufactured, transported, and the manufacturing line techs must be reeducated on the right way to set up them. We’re speaking plenty of hours of labor right here for most likely tens of individuals. And so they’re already actually busy!
As a substitute, Ford took the easy route. One name to the amp provider—”Hey, we will’t get chips. Simply ship us the subwoofer amps unpopulated and put a pink X on them.” Accomplished. One name to the subwoofer provider—”Hey, don’t trouble placing magnets or coils within the Bronco subwoofers. Simply ship us dummies with the cones put in.” The suppliers reduce out the pointless processes, Ford will get near-identical components, and modifications nothing on its finish barring a small reconfiguration to the audio software program.
Plug and play upgrades are doable, however some select to make use of aftermarket amps as an alternative.
Some have additionally speculated that eradicating the subwoofer or related components might have affected the Bronco’s crash take a look at approval. That one’s exterior my wheelhouse, however my engineering spidey-sense says eradicating a speaker isn’t a large enough change to rely in that regard. I could possibly be flawed, although, so I’ve raised that with Ford as nicely.
Retrofits Are Doable
By the way, whereas Ford declined to supply retrofits, that doesn’t imply they’re not doable. Loads of homeowners have pursued subwoofer installations on their very own, and it’s really remarkably straightforward. All as a result of Ford left nearly all the pieces in place!
For the amp, the dummy will be changed with a working model half numbered for the Ford Fusion. It plugs straight in. As for the subwoofer, a Kicker 6.75″ sub is a standard selection. Then, all that’s required is a small modification with a FORScan OBDLink instrument to allow the subwoofer output within the audio system.
Performing these easy mods will get the Bronco’s sound system a lot nearer to how the producer initially meant. No extra will the low frequencies go under-represented!
In the end, some will grouse at Ford for not pursuing a retrofit marketing campaign itself. As demonstrated by many homeowners, it’s not troublesome to pop off some trim items and put the working components the place they’re purported to go. As a substitute, amidst a troublesome manufacturing surroundings, Ford selected a better method out that received product to prospects and it washed its fingers of the entire state of affairs. Plus, it gave Bronco homeowners a enjoyable weekend challenge within the course of. No hurt, no foul?
In any case, it provides us an perception on how bizarre manufacturing will be at bigger scales. Certain, it might sound less complicated for Ford to simply omit components when it may well’t get them. However actuality is usually extra advanced! Massive automakers seldom do something for silly or frivolous causes, exterior of design and product planning, anyway. Dummy components typically exist for good causes, even when they’re seemingly ineffective.
Picture credit: Amazon, BuckleUpButtercupTV through YouTube screenshot