The Secret Six-Step Inspection Every Ford Ranger Must Pass Before Hitting the Road

The Ford Ranger is a standout in South Africa’s competitive bakkie market, renowned for its quality, reliability, and durability. But what many don’t know is the rigorous inspection process every Ranger undergoes before it leaves Ford’s Silverton Manufacturing Plant in Pretoria. This six-step Customer Acceptance Line (CAL) ensures that every Ranger meets the highest standards, solidifying its reputation as a global leader in the segment.

Ford Ranger: A Global Success Story

Since its inception, the Ford Ranger has become a symbol of excellence in South Africa’s automotive industry. Produced at Ford’s Silverton Plant, one of only five Ranger manufacturing hubs worldwide, the bakkie has left an indelible mark on businesses, communities, and individuals alike. Between 2000 and early 2024, over one million Rangers rolled off the production line, with a new vehicle completed every two minutes.

But what truly sets the Ranger apart is the meticulous quality control process it undergoes before reaching customers. Let’s take a closer look at the six-step inspection every Ranger must pass.

The Six-Step Customer Acceptance Line (CAL)

1. Dark Room Inspection

In a completely dark room, inspectors meticulously check the headlights, taillights, instrument cluster, SYNC® screen, and all interior lighting. This ensures proper brightness, alignment, and functionality.

2. Hands-On Inspection

Inspectors run their hands across every surface of the vehicle, feeling for imperfections and ensuring precise panel alignment. Every button, switch, and control is tested—pressed, poked, clicked, and pulled—to guarantee flawless operation.

3. Systems Check

A comprehensive diagnostic test ensures all electrical components are connected and functioning correctly. This step is crucial for identifying any potential issues with the vehicle’s electronics.

4. AI Eyes

Ford’s Mobile Artificial Intelligence Vision System (MAIVS) uses advanced algorithms to scan the vehicle’s exterior for flaws. This includes checking for missing or crooked badges, paint imperfections, and other visual defects.

5. Rainstorm Simulation

The Leak Test simulates a five-minute monsoonal downpour. High-pressure water jets blast the vehicle from every angle, testing its watertight seals. Inspectors carefully check doors, lights, and rubber seals for any signs of water ingress. The water used is collected, treated, and reused, aligning with Ford’s sustainability practices.

6. Squeak-and-Rattle Track

The final step involves a 320-meter-long track designed to simulate real-world driving conditions. Featuring uneven cobblestones, angled irons, and other challenging surfaces, the track ensures there are no unwanted noises and that the suspension and steering operate flawlessly.

A Legacy of Excellence

The Ford Ranger’s commitment to quality has earned it numerous accolades, including the prestigious 2023 South African Car of the Year title—the first bakkie to achieve this honor. It has also won CAR Magazine’s Best Double Cab Bakkie every year since 2011 and topped the CAR Bakkie Shootout in 2021. Additionally, it remains a consistent finalist in the Cars.co.za Consumer Awards and has earned top honors in The Star Readers’ Choice Awards.

Why the Ranger Stands Out

The Ranger’s success is a testament to Ford’s dedication to quality and innovation. By combining advanced technology, rigorous testing, and skilled craftsmanship, Ford ensures that every Ranger delivers on its promise of durability, comfort, and performance.

“The trained eyes and precise hands of Ford’s Customer Acceptance Line inspectors are essential in ensuring every Ranger meets the highest standards,” says Suresh Babu, Plant Manager at Silverton Vehicle Operations. “Their meticulous attention to detail provides the final seal of approval before the vehicle reaches its new owner.”

The Ford Ranger’s six-step inspection process is a shining example of Ford’s commitment to quality and customer satisfaction. From the dark room to the squeak-and-rattle track, every step is designed to ensure that the Ranger lives up to its reputation as one of South Africa’s most trusted and celebrated vehicles. Whether on the road or off, the Ranger continues to set new benchmarks in the bakkie segment, proving why it’s a global favorite.

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