Chris May
Analyst · Bank of America
Thank you, David, and good morning, everyone. I will cover the financial details of our third quarter of 2020 results with you today. I will also refer to the earnings slide deck as part of my prepared comments. So let's go ahead and start with sales.
Sales in the third quarter of 2020 were $1.41 billion compared to $1.68 billion in the third quarter of 2019. Slide 6 shows a walk down of third quarter 2019 sales to the third quarter of 2020 sales. First, we stepped down our third quarter 2019 sales by $155 million to reflect the sale of the U.S. casting business unit that was completed in December of 2019. Next, we add back the impact of the GM work stoppage from the third quarter of last year. Then we account for the unfavorable impact of COVID-19 on third quarter 2020 sales, which we estimate to be approximately $87 million. One note about the estimated COVID-19 impact, nearly 2/3 of it related to lower than expected sales in Brazil and India. While these markets are relatively small for AAM, they still were significantly impacted by the global pandemic during the quarter. On a year-over-year basis, we are also impacted by or by AAM -- by GM's exit of its Thailand operations by approximately $15 million. And the transition from a rear beam axle to a new lightweight and highly efficient independent rear drive axle for GM's new full-size SUV impacted sales by approximately $55 million.
Other volume and mix was positive by $17 million, mainly driven by strong light truck mix in North America. Pricing came in at $10 million year-over-year impact and metal market pass-throughs and foreign currency accounted for a decrease in sales of approximately $15 million year-over-year.
Now let's move on to profitability. Gross profit was $249.8 million or 17.7% of sales in the third quarter of 2020 compared to $248.7 million or 14.8% of sales in the third quarter of 2019. Adjusted EBITDA was $297.1 million in the third quarter of 2020 or 21% of sales. This compares to $265.8 million in the third quarter of 2019 or 15.8% of sales. This marks the first time in AAM's history to post a 20%-plus adjusted EBITDA margin quarter.
Let's walk through how we got there. You can see a year-over-year walk down in adjusted EBITDA on Slide 7. Similar to sales, we backed out the third quarter 2019 U.S. casting EBITDA to provide a comparable figure after the sale of the U.S. casting business unit and added back the third quarter 2019 profit impact of the GM work stoppage. We then estimate that lower sales, as a result of COVID-19, impacted EBITDA by approximately $16 million in the third quarter of 2020. Other volume and mix, which also includes the impact of the GM Thailand exit and the full-size SUV transition was approximately $10 million. There were a few other significant items to call out as it relates to our EBITDA walk. The first thing to note when customer reimbursement settlement payments were approximately $22 million in the third quarter of 2020. This primarily relates to past engineering and design costs for new product development that were reimbursed from one of our customers in the third quarter as part of our R&D cautionary arrangement for our future program.
This resulted in lower net R&D in the quarter and ultimately, higher EBITDA.
Another major factor in our financial performance this quarter was our cost reduction savings, which were approximately $24 million in the third quarter of 2020 compared to the third quarter of 2019. These savings came in slightly higher than those realized in the second quarter and aligned with achieving our target of a total of $60 million of cost savings in 2020.
We experienced about $3 million in COVID-related costs in the quarter. Back in May, we originally expected to incur about $40 million of COVID-related costs in 2020, but we have been able to mitigate and avoid many of these potential expenditures. We now expect to spend approximately $15 million in 2020 for COVID-related startup and inefficiency costs.
We did see a benefit from metal market and foreign currency of approximately $8 million, mainly driven by FX. And overall, our operations teams continued to perform on productivity improvements on top of these significant cost reductions for an additional net $4 million. Even when backing out, customer reimbursement and commercial settlement, along with the favorable foreign currency that was realized in the quarter, it was an impressive operating and financial performance for AAM in the third quarter.
As it relates to restructuring and acquisition-related costs, we incurred $9.7 million of such costs in the quarter. We also recorded $8.6 million of net expenses related to the Malvern fire that David previously mentioned. These charges are primarily related to the write-down of property, plant and equipment as a result of the damage of the fire, net of estimated insurance proceeds less our applicable deductible. As this event was experienced at the end of the quarter, we continue to assess the extent of the damage caused by the fire and related impact. These costs have been excluded from adjusted EBITDA and adjusted EPS.
Let's take a look at SG&A expense. SG&A, including R&D, in the third quarter of 2020 was $66.5 million or 4.7% of sales. This compares to $92.7 million or 5.5% of sales in the third quarter of 2019. R&D spending was approximately $18 million for the third quarter of 2020 compared to $37 million in the third quarter of 2019. The decrease in R&D on a year-over-year basis primarily reflects the previously discussed ED&D recovery.
Now let me cover interest and taxes. Net interest expense in the third quarter of 2020 was $50.5 million as compared to $52.1 million in the third quarter of 2019. We continue to experience lower interest expense costs as we pay down our outstanding debt. Income tax was a benefit of $22.5 million in the third quarter of 2020 as compared to $40 million in the third quarter of 2019. You may remember last quarter that we recorded a valuation allowance of $36 million against our deferred tax assets related to U.S. interest expense carryforwards. During the quarter, the IRS and treasury department issued final regulations and additional proposed regulations that included important changes and clarifications and ultimately resulting in us to release this valuation allowance in the third quarter of 2020. Our effective income tax rate when adjusting for special items and the valuation allowance reversal was approximately 15% in the third quarter of 2020. We expect our tax rate in the fourth quarter to be in the 15% to 20% range.
Taking all of these sales and cost drivers into account, GAAP net income was $117.2 million or $0.99 per share in the third quarter of 2020 compared to a net loss of $124.2 million or $1.10 per share in the third quarter of 2019. Adjusted earnings per share was $1.15 in the third quarter of 2020 compared to $0.58 per share in the third quarter of 2019.
Now let's move on to cash flow and the balance sheet. We define free cash flow to be net cash provided by operating activities less capital expenditures, net of proceeds received from the sale of property, plant and equipment. AAM defines adjusted free cash flow to be free cash flow excluding the impact of cash payments for restructuring and acquisition-related costs.
Net cash generated by operating activities in third quarter of 2020 was $249.5 million. Capital spending, net of proceeds from the sale of property, plant and equipment was $40.5 million in the third quarter of 2020. Cash payments for restructuring and acquisition-related costs for the third quarter of 2020 were $8.2 million. Reflecting these activities, AAM's adjusted free cash flow in the third quarter of 2020 was $217.2 million. This is a quarterly record for AAM to reflect strong operational profits, significantly lower capital spending and implementation of cost and cash savings initiatives. It also includes an income tax refund we received of approximately $31 million related to the utilization of net operating losses under the provisions of the Cares Act.
From a debt leverage perspective, we ended the quarter with a net debt to LTM adjusted EBITDA or net leverage ratio at 4.7x. This is down from the second quarter of 2020 on the strength of our EBITDA and cash flow generation.
Liquidity at the end of September was approximately $1.5 billion. We had over $0.5 billion of cash and no amounts outstanding on our revolver at September 30, 2020, and no significant debt maturities until 2024.
David has gone through the details of our updated full year financial targets, so I will not repeat them. I believe our continued performance in 2020 highlights AAM's ability to adapt and flex our cost structure. Our cost savings actions have helped drive significant operating profitability and cash flow generation in a turbulent year. We are busy working to deliver and build upon these cost savings actions that we believe will position us well for a successful 2021. Stay tuned for more detailed guidance on next year as we turn the calendar.
Meanwhile, we look to close out 2020 on a strong note and continue to make important progress on innovative next-generation electrification technology that will power our opportunities for growth for a long time to come.
Thank you for your time and participation on the call today. I'm going to turn the call back over to Jason, so we can start the Q&A. Jason?