Product Development Engineer - Rear Axle Design & Release

In This Position

Join our team as a Design and Release Engineer for the Ford Expedition and Lincoln Navigator Independent Rear Suspension (IRS) Rear Axle. You will hold critical engineering responsibility for a leading drivetrain system within the industry, directly contributing to the superior performance and segment‑defining capabilities of the Expedition and Navigator. We’re actively developing exciting new designs, and your talent is essential to bringing these innovations to market.

As a Design & Release Engineer within the Underbody Systems Engineering (UnSE) organization, you will be the primary owner of the Independent Rear Suspension (IRS) Rear Axle for the iconic Ford Expedition and Lincoln Navigator vehicle lines. This critical platform is exclusively built in our North American assembly plants, notably the Kentucky Truck Plant, with the axle assemblies manufactured at the Sterling Axle Plant in Sterling Heights, Michigan.

You will be instrumental in bridging engineering design with manufacturing reality, directly collaborating with skilled engineering teams and operators at both assembly and component plants. This role involves optimizing existing designs for streamlined assembly and maximizing the performance our customers expect, while also spearheading new design implementations. You will also leverage our onsite dynamometer cells, actively supporting comprehensive testing, teardown, and in–depth analysis of axles to ensure program Design Verification Plans (DVPs) are met and technical issues are swiftly resolved.

• Lead the design, development, and release of innovative engineering solutions to significantly enhance the performance, efficiency, and durability of the IRS Rear Axle system
• Drive cross‑functional collaboration with Design, Manufacturing, Quality, and other engineering teams to ensure seamless integration and successful implementation of new technologies and processes
• Manage and oversee rigorous testing and validation protocols, guaranteeing the highest levels of reliability, safety, and compliance for the IRS Rear Axle
• Conduct in‑depth data analysis and provide critical technical insights to inform strategic product improvements and optimizations
• Maintain expert‑level knowledge of the latest automotive industry trends, emerging technologies, and regulatory landscapes pertinent to axle systems
• Actively participate in and contribute to design reviews, technical meetings, and comprehensive project planning sessions
• Serve as a technical resource, leading the resolution of complex engineering issues and mentoring other team members

• Bachelor’s degree in Mechanical Engineering or a related field; or equivalent combination of education and experience.
• Minimum of 2 years of experience in automotive engineering.
• The D&R Engineer is responsible for managing product release CAD and BOM structures, including assembly positioning and mass attribute analysis. This role also includes facilitating supplier data integration and developing CAD studies to support and drive design improvements.

• Master’s degree in Mechanical Engineering or a related discipline.
• Demonstrated experience with performance and durability testing, including both dynamometer and in‑vehicle validation.
• Robust understanding and application of Systems Engineering principles.
• Familiarity with Ford’s Design and Release Tools, such as WERS, Teamcenter, FEDE, ED&T, and processes including DVP, DFMEA, Quality History, and Warranty Analysis.
• Proven strong problem‑solving abilities and a creative approach to developing innovative engineering solutions.
• Proficiency in Microsoft Office Suite and relevant engineering software tools for simulation, analysis, and modeling (e.g., CAD, CAE software).
• Exceptional communication, presentation, and interpersonal skills.
• Demonstrated ability to thrive in a team‑oriented environment and effectively collaborate with diverse cross‑functional teams.
• Ability to travel occasionally (estimated less than 10%).

You may not check every box, or your experience may look a little different from what we’ve outlined, but if you think you can bring…