Fire at New York Novelis Plant Deals Major Blow to Ford

The plant served as a critical supplier of aluminum sheet for Ford’s most lucrative models, from the F-150 pickup to the Expedition SUV.

To keep production of its flagship F-Series trucks running, Ford has been forced to halt output of several less popular models. The loss of one of its largest aluminum suppliers — a material central to the automaker’s brand identity as a leader in lightweight construction — has inevitably led to major disruptions. Now, the ripple effects are beginning to hit other automakers, including Stellantis.

According to Auto30.com, Stellantis has temporarily suspended assembly of the Jeep Wagoneer and Grand Wagoneer at its Warren, Michigan, plant. The production line will remain idle at least through the first week of November. While the SUVs aren’t fully aluminum-bodied, many exterior panels — including the hood and all doors — are made from aluminum, leaving them dependent on Novelis supplies.

Stellantis has also decided to reallocate its limited aluminum stock, prioritizing production of the Ram 1500 — the company’s best-selling pickup, built at the nearby Sterling Heights facility.

Ford, however, has taken the hardest hit. Production of the F-150 Lightning, Expedition, and Lincoln Navigator has been paused so the remaining aluminum inventory can be redirected toward building conventional F-150 and Super Duty trucks. Assembly of the SUVs has been completely halted for two weeks, and output of the electric Lightning may remain frozen even longer. Reports indicate that F-150 production has been cut roughly in half and will likely stay that way through the end of October.

Novelis doesn’t expect to restart the New York plant before next year, meaning the aluminum shortage will continue for months. Even after operations resume, the facility won’t immediately return to full capacity — signaling continued supply disruptions and potential price increases across the industry.