The 2004 Ford F-250/F-350 Super Duty (also, Excursion / Econoline) Exterior Mirror is primarily used for cargo and towing.  The portrait style mirror is manually telescoping for towing large trailers or wide loads.  It has power/heated glass and integrated turn signal.  The Super Duty mirror has 75+ parts and weighs approximately 10 lbs.  The team and other customers were also disappointed to learn that although the competition offers a power-telescoping feature on their mirror, the Ford mirror does not offer this feature to the customer. So we have redesigned the side view mirror to incorporate a power-telescoping feature to increase customer satisfaction while reducing weight and parts.  The weight has been reduced by 25% which improves the fuel economy of the car.  The assembly efficiency was improved by eliminating or combining parts and redesigning parts for easier assembly, such as snap fits replace original screws on the mirror casing.  For the telescoping ability of the mirror, a motor worm gear design gives the mirror the correct extension time and length with minimal weight and space used.  This redesign was developed by Aaron Freudigman, Justin Gillespie, and Ami Kapadia in Winter 2004, instructors: Prof. Sridhar Kota, and Mentor Dr. Donald Malen.


 

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