Group 19 - Ford F-150 Power Wheels: Gate 4 Product Archaeology

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Product Reassembly


In this part of the gate group 19 re-assembled their product. While re-assembling the product the group wrote down all steps that occurred along with the tools and binders use to do so. The group also gave each step its own numerical difficulty rating based on the difficulty each step took to accomplish. This part of the gate also contains the challenges in which the group had to overcome while reassembling the product.


Part A: Subsystem - Cargo Bed

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
1 Inner Cargo Bed Door 31 Outer Cargo Bed Door 32
Human Force interlocked both pieces using plastic connections, no screws 1
2 Inner Cargo Bed Door & Outer Cargo Bed Door 31 & 32 Cargobed 2
Human Force cargo bed door assembly forced into plastic sliding hinge in cargobed 2
3 Inner Cargo Bed Door 31 Outer Cargo Bed Door 32
8 Screws [100] Phillips P2 Screwdriver after the cargo bed assembly was put in the cargo bed, it was then binded together with 8 screws 2

Figure 1: Cargo Bed Reassembled

Part B: Subsystem - Front Grille

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
4 Grille Support 12 Front Grille 11
Human Force large force with several people was needed 3
5 Lower Headlight x 2 11d Front Grille 11
Human Force popped on 1
6 Headlight Cover x 2 11b Headlight x 2 11c
Human Force set in place 1
7 Headlight Cover x 2 & Headlight x2 11b & 11c Front Grille 11
1 Screws [100] Phillips P2 Screwdriver 1 screw each side, 2 screws total 2
8 Grille Piece 11a Front Grille 11
3 Screws [100] Phillips P2 Screwdriver 2

Figure 2: Front Grille Reassembled

Part C: Subsystem - Left/Right Gearbox

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
9 Tope Gear, Middle Gear 1, Middle Gear 2, & Bottom Gear 23c, 23d, 23e, 23f Gearbox Inner Casing 23a
gears were simply put into place, all gears covered in grease 1
10 Gearbox Inner Casing 23a Gearbox Outer Casing 23b
4 Screws [100] Phillips P2 Screwdriver also used 4 plastic clips as well as screws, 8 total screws for left and right gearboxes 2
11 Rear Motor 27 Gearbox 23
1 Flathead Screw 1/8 Flathead Screwdriver 1 flathead screw for each left and right motor, 2 total, placed rear motor into gearbox snugly 2

Figure 3: Left/Right Gearbox Reassembled

Part D: Subsystem - Radio

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
12 Volume Knob, Refresh Button, Search Button, Reset Button, & Music Button 34j, 34k, 34l, 34m, 34 n Radio Middle 34b
Human Force popped in 1
13 Radio Button Mount 34i Radio Middle 34b
6 Screws [95] (with washer heads) P1 Phillips Screwdriver 2
14 Circuit Board 34h Full Circuit Board Cover 34f & 34g
Human Force popped on 1
15 Circuit Board Cover (Back) 34f Circuit Board Cover (Front) 34 g
6 Screws [96] P1 Phillips Screwdriver 2
16 Speaker Holder 34d Radio Back 34c
2 Screws [98] P1 Phillips Screwdriver 2
17 Full Circuit Board Cover 34f & 34 g Radio Middle 34b
4 Screws [97] P1 Phillips Screwdriver slipped in and inserted screws 2
18 Radio Cover 34a Radio Middle 34b
4 Screws [97] P1 Phillips Screwdriver screwed on from the back of the radio 2
19 Radio Back 34c Radio Middle 34b
6 Screws [102] P1 Phillips Screwdriver 2

Figure 4: Radio Reassembled

Part E: Subsystem - Dashboard

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
20 Radio 34 Dashboard 36
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3 Screws [100] (with plastic clips) P2 Phillips Screwdriver 2
21 Steering Wheel 4 Steering Column 13
Human Force put together by sticking 14. Pin though 18. Wire Clips & 4. Steering Wheel, holding them together. Required multiple tries to perform this step because the pin required a lot of force to force through 3
22 Steering Wheel Cover 6 Steering Wheel 4
Human Force forced on 1
23 Steering Column, Steering Wheel, & Steering Wheel Cover 13, 4, 6 Dashboard 36
Human Force popped in 1

Figure 5: Dashboard Reassembled

Part F: Subsystem - Seat

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
24 Seat Pillar 37 Seat 5
3 Screws [100] P2 Phillips Screwdriver 3 screws on each side, 6 total 2
25 Headrest x 2 38 Seat 5
1 Screw [100] P2 Phillips Screwdriver 1 screw plus a plastic connection on each side, 2 total 2

Figure 6: Seat Reassembled

Part G: Main Chassis

\'\'\'Step\'\'\' \'\'\'Part Attached\'\'\' \'\'\'Part #\'\'\' \'\'\'Onto Part\'\'\' \'\'\'Part #\'\'\' \'\'\'Picture\'\'\' \'\'\'Binders\'\'\' \'\'\'Tools Used\'\'\' \'\'\'Notes\'\'\' \'\'\'Difficulty\'\'\'
26 Pedal 30 Main Chassis 1
Human Force snapped pedal onto chassis by wiring and plug 2
27 Front Axle Assembly 29 Main Chassis 1
1 Screw [100] P2 Phillips Screwdriver 2
28 Battery Holder 28 Main Chassis 1
2 Screws [101] P2 Phillips Screwdriver 2
29 Top of Gear Shifter 26a Bottom of Gear Shifter 26b
4 Screws [100] P2 Phillips Screwdriver 2
30 Top and Bottom of Gear Shifter 26a & 26b Main Chassis 1
2 Screws [100] P2 Phillips Screwdriver also connected with plug and wires, all wiring was then put in place along the center of the console 2
31 Wire Concealer 24 Main Chassis 1
Human Force forced on with plastic connections 1
32 Center Console Piece 25 Main Chassis 1
Human Force forced on with plastic connections 2
33 Rear Wheel Axle 22 Gearbox & Main Chassis 23 & 1
Human Force slid through the left and right gearboxes standing upward and through the main chassis 1
34 Rear Wheel 10 Rear Wheel Axle 22
Human Force slid on 1
35 Hubcap x 2 3 Rear Wheel 10
Human Force put into place through 18. wire clips 1
36 Side Mirror x 2 21 Main Chassis 1
2 Screws [100] P2 Phillips Screwdriver 2 screws on each side, 4 total 2
37 Sideskirt x 2 19 Main Chassis 1
2 Screws [100] P2 Phillips Screwdriver 2 screws on each side, 4 total 2
38 Cargo Bed Assembly 2 Main Chassis 1
6 Screws [100] P2 Phillips Screwdriver 2
39 Battery 8 Battery Holder 28
Human Force slipped battery on top of the battery holder 1
40 Front Grille 11 Main Chassis 1
8 Screws [100] P2 Phillips Screwdriver had to reach in front of wheel, 2 screws under the car 3
41 Windshield Frame 33 Dashboard 36
Human Force 1
42 Dashboard 36 Main Chassis 1
8 Screws [100] P2 Phillips Screwdriver connected wire connecting dashboard to main chassis, simultaneously slid into windshield frame onto dashboard 2
43 Steering Column Cap 15 Steering Column 13
1 Screw [100] P2 Phillips Screwdriver had to turn the car on its side to access screw, very difficult to turn screwdriver in a compact area 3
44 Seat Assembly 5 Main Chassis 1
4 Screws [100] P2 Phillips Screwdriver 2
45 Hood 7 Main Chassis 1
Human Force forced 2 plastic connections into the 2 slots in front of the chassis 1
Figure 7: Product Before and After Reassembly


The Ford-150 Power Wheels contained 9 different types of screws. The most common one was a #8 by 3/4 inch screw, which Group 19 labeled [100] for Group 19\'s reference. The 8 other types of screws are listed and shown in the picture below.

Screws in order from left to right: [95],[96],[97],[98],[99],[100],[101],[102],[103]


Tools used in the reassembly of the Ford-150 Power Wheels

\'\'\'Tool Name\'\'\' \'\'\'Image\'\'\' \'\'\'Usage\'\'\'
P2 Phillips Screwdriver
G19 P1 Screwdriver.JPG
The primary tool used for dissection. Used to do most of the screwing of the product because most of the fasteners are Phillips screws.
P1 Phillips Screwdriver
G19 P2 Screwdriver.JPG
Used with the smaller sized Phillips screws of the product. Used mostly for the radio reassembly.
1/8 Flathead Screwdriver
G19 Flathead.jpg
Used for unscrewing slot screws and for prying out plastic components. Used moderately for force puporses.
Human force
G19 Fist.jpg
Required for when there were no screws, but plastic connections. Used commonly for reassembly of plastic components.


The reassembly of the Ford F-150 Power Wheels was relatively easy for Group 19 although there were some challenges that hindered the procedure.

  • \'\'\'Recorder keeping up with the reassemblers\'\'\'
  • \'\'\'Putting electrical wiring in place\'\'\'
  • \'\'\'Following the dissection procedure in reverse\'\'\'

The first challenge dealt with the recorder of the group. Group 19\'s recorder was on a laptop writing out all of the steps of the reassembly procedure on Microsoft Excel. The recorder often found it difficult to keep up with the reassemblers and type up everything that they were doing. Often times the reassemblers would get ahead of the recorder and the recorder would miss typing up a step. To resolve the challenge the group leader made sure that the reassemblers waited after each step to make sure the recorder could catch up and type up the required information.

The second challenge was putting the electrical wiring of the product in place. It was confusing to the figure out which plug and wire went where on the main chassis since multiple components used the electrical wiring, such as the 12 volt battery, rear motors, gear shifter, pedal, and radio. To overcome this challenge the reassemblers saw which plugs fit in what component. Also, Group 19 took a pictures of the electrical wiring in place before dissection. The reassemblers used the pictures of the wiring as a guide. After the wiring was placed in where the reassemblers thought it was placed, the electrcal parts of the product functioned as they originally did.

The last challenge was actually following the dissection procedure in reverse. Group 19 quickly learned that the dissection procedure was not broken into enough steps for complete clarity and some of the information in the procedure was incorrect. This made it hard to follow for the reassembly. The deal with this challenge, the reassemblers took more time to look at the components and see what would make sense to put together, using the dissection procedure for some reference. This made the procedure of reassembly more steps than the dissection. Group 19 also corrected the mistakes made in the dissection procedure.

Ease of Resassembly


During the groups reassembly the group put back together the project from the individual components to the completed product. In doing so multiple steps were required from getting from the start to the finished product. Since each step was different, the group wanted to show how much different each step actually was from one another. They did this by implementing a difficulty scale to show the differences in difficulties of the steps. Also the group found a few differences when translating the step by step from the dissection to the reassembly. The group initially thought that the dissection manual developed in gate 2 could just be read backwards, but that didn’t work for a number of cases while reassembling the product.

Difficulty Scale

The difficulty scale for the reassembly of the Ford F-150 Power Wheels is as follows:

  • \'\'\'1\'\'\': Very Simple
  • \'\'\'2\'\'\': Simple
  • \'\'\'3\'\'\': Moderate
  • \'\'\'4\'\'\': Difficult
  • \'\'\'5\'\'\': Very Difficult

A difficulty of 1 implies the almost no difficulty for the step. The steps of reassembly that Group 19 deemed a 1 difficulty was putting on a part that required no screws. The part was held together using a simple plastic connection that required minimal human force to attach. Also only one person was required to perform the step. An example step in the procedure that had a 1 difficulty was Step 1 in which the inner cargo bed door was simply attached to the outer cargo bed door. No screws were required for this step and little force was needed to put together the plastic connections.

A difficulty of 2 implies a moderately easy step. The steps of reassembly that Group 19 deemed a 2 difficulty was attaching parts that required one or more screws. A P1 Phillips, P2 Phillips, or flathead screwdriver was required to perform the step. Only one person was needed to perform the step but more group members assisting may have minimized the time for the step. An example step in the procedure that had a 2 difficulty was Step 8 in which the grille piece was attached to the front grille. The step required 3 screws that required a screwdriver, which is slightly more difficult then simply using force to attach simple plastic connections.

A difficulty of 3 implies a step of moderate difficulty. The steps of reassembly that Group 19 deemed a 3 difficulty may have used plastic connections, screws, or a combination of both. If screws were present, they were in hard to reach places of the vehicle. A screwdriver or a large amount of force was required to perform the step. Multiple group members and multiple attempts were needed to perform the step. An example step in the procedure with a 3 difficulty was Step 3 in which the steering column cap was attached to the steering column. Multiple group members were needed to perform the step. One group member had to use human force to put the vehicle on its side and keep it from tipping. Another group member had to screw on the steering column cap to the steering column underneath the car. The screw was also in a very compact area so it took multiple attempts to finally screw it in completely.

No steps for the reassembly were deemed a 4 or 5 difficulty by Group 19. There were no steps in the procedure that Group 19 thought were difficult or very difficult. The highest difficulty in reassembly was only a moderate difficulty. The reason for this is that to product is basically a toy and not made of complex systems or connections. If there were steps with a 4 or 5 difficulty, they may have required extreme force, a large amount of screws in unaccessible areas, are required more than 2 group members.

Reassembly/Disassembly Relationship

The procedure for the reassembly of Ford F-150 Power Wheels is almost reverse of the procedure of the dissection procedure. There were some minor differences between the processes.

The time to complete the reassembly of the product was slightly longer than that of the dissection. The reason for this is because breaking down something is always simpler than to build something. The reassembly might have taken a significant amount of time longer to perform if the steps for dissection were not recorded.

The difficulty of reattaching components was about the same as taking apart components though. Screwing and unscrewing doesn\'t have a significant difficulty change. Reattaching components with plastic connections was slightly easier than pulling apart those components though.

The procedure listed above for reassembly has more steps than the dissection procedure because Group 19 broke some steps of the dissection into multiple parts. This makes it more clear for anyone who wished to attempt reassembly of this product.

The plan of the dissection was taking major subsystems (dashboard, cargo bed, front grille, and gearbox) off of the main chassis and then breaking down those subsystems even further. For reassembly, Group 19 added additional separate subsystems to the procedure: radio and seat. In the original dissection procedure, the breakdown of the seat was included in the main chassis dissection and the breakdown of the radio was included in the dashboard dissection. Group 19 chose to include the reassembly of these additional subsystems for greater clarity for the final part of reassembly, which is putting the reassembled major subsystems on the main chassis.

Design Revisions


In this part of the assignment group 19 looked at three possible revisions to their product on a system level. The three revisions that the group decided to look at were shock absorbers, a different radio power supply, and four-wheel drive capability. The group not only looked at the advantages of having these revisions done to their product but they also looked at how the Four Factors (economic, global, societal, and environmental) would affects the companies decisions in installing such revisions.

Alternate Power Source for Radio

Figure 8: 12 Volt Battery

One of the design revisions at systems level Group 19 thought of was changing the power source for the radio of the F-150 Power Wheels. Instead of having 4 “C” Alkaline Batteries to power the radio system, we agreed a better revision would be to connect the radio directly to the 12 Volt Battery that powered the rest of the F-150 Power Wheel. From the environmental view point, reconfiguring the power source of the radio would be seen as a beneficial factor. The result of not using the 4 “C” Alkaline batteries for the radio system would be the reduction of pollution to the environment seeing that the disposal of these batteries would not be necessary after they stopped working. Also at an economic level the consumer would benefit from this design vision because they would not have to purchase extra “C” Alkaline Batteries; adding to the after cost of the F-150 Power Wheel. But one economic concern that would have to be looked further into would be the power consumption of the radio from the 12V Battery, which could lead to the need for a more powerful and thus expensive battery. Also at which could be seen as a global issue, this systems design revision could make the radio usable to consumers in areas where batteries could potentially be hard to access and purchase. At last one of the bigger impacts of this design revision at systems level could be seen as a social impact for the consumer. As the radio is now, the consumer must take apart the radio to install the 4 “C” Alkaline Batteries to power the radio. This design revision would eliminate this task for the consumer making the radio compatible right out of the box and user friendly by removing required service by the consumer. So in conclusion the positive results (environmental, economic, global, and social) from this design revision could help make the F-150 Power Wheel more appealing to consumers, which could thus increase sales and profits.

Shock Absorber Springs

Figure 9: Shock Absorbers

Another design change we would recommend is the addition of springs to act as shock absorbers on all four wheels. The shock absorbers would be a system that includes nothing more than a cylinder, a piston, a spring, and a lubricant (typically oil). Adding shock absorbers would provide a much more comfortable ride for the users, especially on off-road terrains. This would give the user a much smoother ride, improving the overall quality of the product. The shock absorbers would improve the quality of entertainment for the user, making it a plus point from the societal point of view. From a global perspective, the shock absorbers would allow the user to adventure into more extreme terrain than ever before. Besides that, the vehicle would still be environmental friendly, as the parts used to make the shock absorbers are biodegradable and can also be recycled. From the environmental point of view the additions of shock absorbers do not pollute the environment. Economically, the addition and installation of the shock absorbers would increase the quality of the vehicle as well as the price at which the vehicle could be sold at. However, this would also increase the cost price of the vehicle. The shock absorbers do not require periodical servicing. However, if a shock absorber were to fail, it could easily be replaced with a new one. Instructions on how to go about replacing the shock absorbers should be included in the instruction manual and spare shock absorbers should be sold separately. Even though the shock absorbers would increase the price of the vehicle, the comfort that it brings outweighs the increase in cost, as many would be willing to spare a few extra bucks for a much more comfortable ride. As a whole, the reason for the shock absorbers would be to give the user a more comfortable ride while giving the rider a more genuine experience that would also make the user feel as though he is driving the real Ford F-150.

Four-Wheel Drive Capability

Figure 10: Four Wheel Drive

Another design revision we would recommend is to upgrade the product to contain a four wheel drive capability. The truck currently is a rear wheel drive vehicle; the wheels rotate due to the two rear motors which are attached to the rear axle which in turn cause the wheel s to rotate. With all four wheels being powered by motors when the pedal is hit, the truck will have a traction increase and will also cut back on the tires slipping on the driving surface with the increase in distributed power and traction. With this addition the product will be able to climb steeper terrains as well as travel on a broader variety of surfaces. For example, the truck will easily break free from slippery terrains without getting stuck. For this to work, we would suggest that an extra gearbox and motor should be added to each of the front wheels. With a revision like this, the product can be used in places with slippery or muddy terrain, which is a plus point for global concerns. The addition of the extra two wheels will have significant impact on the economical concerns of this product. The cost of adding the two gearboxes and motors will increase the price of the product significantly, while to contrast that the vehicle may be sold at a greater price. With this revision, the truck has a better quality and feels more like a Ford F-150 which is a societal factor. Finally, the gearboxes are biodegradable and can be recycled, and also do not emit any harmful elements into the atmosphere, thereby making it environmentally friendly.