At the end of 1968, the Gananoque–Brockville section was bypassed and the final intersection grade-separated near Kingston, making Highway 401 a freeway for its entire 817.9 km (508.2 mi) length.
[7][11] The just-in-time auto parts delivery systems of the highly integrated automotive industry of Michigan and Ontario have contributed to the highway's status as the world's busiest truck route,[12] carrying 60 percent of vehicular trade between Canada and the US.
[1] The highway is one of the major backbones of a network in the Great Lakes region, connecting the populous Quebec City–Windsor corridor with Michigan, New York and central Ontario's cottage country.
[15] By September 2025, the Gordie Howe International Bridge will extend Highway 401 across the Canada–United States border to a connection through Delray to Interstate 75 in Michigan.
[18] Southwestern Ontario is flat, primarily agricultural land, that takes advantage of the fertile clay soil deposited throughout the region.
[42] The east end of this section, running south of Toronto Pearson International Airport, reaches the Highway's widest point, at 18 lanes.
This is also the west end of the third and longest express-collector segment (43.7 km (27.2 mi)) which crosses the rest of the city to Brock Road in Pickering in the east.
[44] The 5 km (3.1 mi) gap with no express/collector split between Highways 427 and 409 is a traffic bottleneck, since the space constraints of the existing flyovers of the at the 401-427 interchange also limit the width of the 401 in this section to eight lanes (widened from the original six).
[11][72] When widening in Scarborough reached the Highland Creek ravine in 1936, the Department of Highways began construction on a new bridge over the large valley, bypassing the former alignment around West Hill.
[11][75] Along with immense improvements to machinery and construction techniques over its six-year course, the war provided planners an opportunity to conduct a survey of 375,000 drivers, asking them about their preferred route to travel to their destination.
The reporter continued, with regard to the eastern section through Scarborough, that it "winds smoothly through pastures across streams and rivers, and beside green thickets.
[88] In 1958, a section bypassing Morrisburg was opened to accommodate traffic displaced from a portion of Highway 2 through The Lost Villages of the Saint Lawrence Seaway.
James Auld, MPP for Leeds and the Minister of Tourism and Information, joined local residents to persuade the DHO to construct an inland bypass.
[98] Despite the expected influx of traffic from the United States for Expo 67 in Montreal, the DHO opted to build the portion east of Ivy Lea after the centennial celebrations.
In 1963, transportation minister Charles MacNaughton announced the widening of Highway 401 in Toronto from four to a minimum of 12 lanes between Islington Avenue and Markham Road.
[136] Between June 1990 and 1998, Highway 401 and Interstate 75 were used for a pilot project named Advantage I-75 to test the reliability and versatility of an automated tracking system for transport trucks.
[140][142] Various other names, including The Killer Highway circulated for a time,[143] but Carnage Alley became predominant following an 87-vehicle pile-up on September 3, 1999 (the start of Labour Day weekend), the worst in Canadian history, that resulted in eight deaths and 45 injured individuals.
[145] On the morning of September 3, the local weather station reported clear conditions due to a malfunction,[144] while a thick layer of fog rolled onto the highway.
[146][147] Immediately following the crash, the MTO installed paved shoulders with rumble strips[148] and funded additional police to patrol the highway, a move criticized as being insufficient.
As part of that project, the Dougall Parkway split with Highway 401 was reconfigured, replacing a one-lane 1950s-era underpass tunnel with a modern high-speed flyover ramp.
[153] This length of the highway is often travelled by a convoy of vehicles carrying a fallen soldier's body, with his or her family, from the military airport at CFB Trenton to the coroner's office at the Centre of Forensic Sciences in Toronto.
[154] The origin of the name can be traced to an article in the Toronto Sun on June 23, 2007, by columnist Joe Warmington, in which he interviewed Northumberland photographer Pete Fisher.
[161] The project included the installation of a tall-wall median barrier, straightening curves and adding additional interchanges on the freeway, allowing it to be easily vacated in an emergency event.
[179][180] On March 3, 2008, the Michigan Department of Transportation and the MTO (in partnership with Transport Canada, the Federal Highway Administration of the United States and the Detroit River International Crossing group) completed a joint assessment on the soils along the Detroit River and determined they could indeed support the weight of a new bridge; the stability of the underlying soil and clay and the impact of the nearby Windsor Salt Mine had caused concern for all parties involved in the project.
[181] Despite protest from area residents,[182] as well as a dismissed lawsuit from Ambassador Bridge owner Matty Moroun,[176][177] it was announced on May 1, 2008, that a preferred route had been selected for the Highway 401 extension which would be named the Windsor–Essex Parkway.
[190] The original North Talbot Road overpass was demolished on August 20, 2011, to make way for the widening of the existing freeway from four through-lanes, however the replacement bridge was closed in December 2013 due to faulty concrete girders and rebuilt by May 2014.
[16] In Southwestern Ontario, several improvements are under way to provide six lanes on Highway 401 from Windsor to Toronto,[203] in response to the higher-than-average accidents occurring on the "Carnage Alley" stretch including the 1999 Labour Day weekend pileup.
Just west of the Highway 8 interchange, the freeway's existing six-span Grand River Bridges (opened in 1960, restriped in the early 1990s from two to three lanes per direction) are being replaced with two new four-span structures, a project scheduled for completion in 2025.
[227] On September 25, 2024, Premier Doug Ford announced that the Ontario government has launched the technical evaluation for the proposed construction of a new driver and transit tunnel expressway under Highway 401.
In Mississauga (just east of Winston Churchill Boulevard), a centre with a unique layout opened in 1991 but closed in 2006, being demolished in 2010 to accommodate the freeway's widening to a collector-express system as well as making way for an OPP station.