Ford Super Duty

Submitted by editor on Mon, 03/07/2011 - 16:23

Ford Super Duty

Ford Super Duty

Manufacturer	Ford Motor Company
Also called	Ford Western (in some Asian countries)
Model years	1999–present
Predecessor	Ford F-250/350
Class	Full-size pickup truck
Layout	Front engine, rear-wheel drive / four-wheel drive

The Ford Super Duty is a line of commercial pickup trucks (over 8,500 lb (3,900 kg) GVWR) introduced in 1998 for the 1999 model year. The F-250 to F-550 Super Duties are assembled at the Kentucky Truck Plant in Louisville, Kentucky. The F-650 and F-750 Super Duties are assembled at the Blue Diamond Truck plant in Mexico.

The Super Duty trucks are larger, heavier built commercial/industrial series pickup trucks with heavier-duty body-on-frame steel ladder frames, axles, springs, brakes, transmissions, more powerful engines, and all other heavier/bigger components (with much higher payload and towing capacities) than the older traditional equivalent F-250, F-250HD (Heavy Duty), and F-350 Ford truck lines. The two-wheel drive and four-wheel drive model frames are the same in the F-250 and F-350 series, making conversion from a two-wheel drive model to a four-wheel drive model less difficult than in other truck models. This is because the '99 model year of the F-series has all the bolt holes in the frame for both two-wheel and four-wheel drive precut by the manufacturer.

First generation (1999–2007)

First generation

Also called	F-250 F-350 F-450 F-550
Model years	1999–2007 1999-present (Brazil)
Assembly	Louisville, Kentucky, United States Silao, Guanajuato, Mexico Valencia, Carabobo, Venezuela São Bernardo do Campo, São Paulo, Brazil
Engine	5.4 L Triton V8 6.8 L Triton V10 7.3 L Powerstroke Diesel V8 6.0 L Powerstroke Diesel V8 3.9 L Cummins B-series Diesel (Brazil)
Transmission	5-speed manual 4-speed 4R100 automatic 6-speed manual 5-speed 5R110W automatic
Wheelbase	137 in (3,480 mm) 141.8 in (3,602 mm) 158 in (4,013 mm) 156.2 in (3,967 mm) 172.4 in (4,379 mm)
Length	222.2 in (5,644 mm) 227 in (5,766 mm) 243.2 in (6,177 mm) 241.4 in (6,132 mm) 257.6 in (6,543 mm)
Width	79.9 in (2,029 mm) 95.5 in (2,426 mm)
Height	76.2 in (1,935 mm) - 81.3 in (2,065 mm)
Related	Ford Excursion

For the 1999 model year, Ford shifted the F-250 and F-350 truck lines to a design mechanically and cosmetically distinct from that of the F-150. The F-350 was not available for 1998, while the F-250 was available that year with the F-150's body. By using two separate but related platforms for F-Series trucks, the inevitable compromises inherent in offering a wide range of load-carrying capacities were avoided. The main competition, General Motors, followed suit for the 2001 model year, when the Chevrolet Silverado HD and GMC Sierra HD were introduced.

These trucks were styled distinctly different for the first time from the smaller F-150 half-ton pickups. They did not share components with the F-150 platform at all (except V-8 gas engines), even though it was still considered an F-series truck. Instead of the aerodynamic look, it was more boldly angular with a raised hood and lowered fenders, somewhat like the fender / hood medium truck style pioneered by the 1994 Dodge Ram pickup. As an industry first, 2 big massive complete ring-style front tow hooks were included. The side windows went lower forward in the door like a commercial medium to heavy duty truck (similar to a Kenworth "Daylight Door"), and the grille was also narrower and taller as if from a larger truck, and in 2001, optional manual telescoping Trailer Tow (TT) mirrors became available.

2002 Ford F-250 with 20-foot (6.1 m) enclosed trailer for four motorcycles

There were three cab options: Standard (2-3 passengers) with two doors, SuperCab (5-6 passengers) with 2 reverse-opening small rear doors (4 doors), and the crew cab with 4 full doors and seats for 5-6 people. The Super and Crew cabs came with 6 ¾-foot and 8-foot (2.4 m) full-size bed options, but the Standard cab was only available with the 8' bed. The F-250 Super Duty would also be the base platform for the short-lived Ford Excursion which was the only passenger SUV larger than the Chevrolet Suburban and its twin, the GMC Yukon XL.

The Ford F-350 Super Duty first generation was also assembled in Venezuela as a commercial small truck from 1999 to 2010. For this market the F-350 featured the 5.4L V8 Triton engine with a 5 speed manual transmission with a choice of 4x2 or 4x4.

The Ford Super Duty trucks are built in Brazil since 2003. Brazilian trucks were widely exported to Australia(F-250), South Africa and Argentina (where they were sold as the F-100).

Engines

The Super Duty had several available engines. A 2-valve per cylinder 5.4 L Modular V8 with 255 horsepower (190 kW) and 350 foot-pounds force (470 N·m) of torque was standard, while the 2-valve per cylinder 6.8 L Modular V10 with 310 horsepower (230 kW) and 425 ft·lbf (576 N·m) of torque was an option. In 1999, power output for the 16V 5.4L V8 increased slightly from 255hp to 260hp. For the 2005-2008 model years, all models equipped with the 5.4L Triton received the 3V SOHC heads. Power was now rated at 300hp with 365 lb/ft of torque. Similarly, the 2005+ Triton V10 received 3-valve heads and output was raised to 362 hp (270 kW) and 457 lb·ft (620 N·m). The 7.3 Power Stroke turbodiesel with 235 horsepower (175 kW) and 500 foot-pounds force (680 N·m)of torque from 1999 to 2000 and upped to 250 hp (190 kW) and 500 ft·lbf (680 N·m) of torque in 2001 to 2002 trucks equipped with an automatic transmission or 275 hp (205 kW) and 520 ft·lbf (710 N·m) of torque for trucks equipped with a manual transmission.

6.0 Power Stroke

The 6.0 Power Stroke with a variable-vane turbo was phased in starting in 2003; this engine produced 325 horsepower (242 kW) and 560 foot-pounds force (760 N·m) of torque. The 6.0 L 32-valve pushrod-actuated Power Stroke single-turbo diesel was modified in 2005, boosting torque to 570 ft·lbf (770 N·m), but power remained the same as the previous version with 325 horsepower (242 kW). Due to impending tighter emissions requirements, along with a very high warranty exposure and over 500 full vehicle buybacks (175 by one northern California law firm alone), 2007 models were the last to include the 6.0 L diesel.

Transmissions

Four transmissions were available. A standard 5-speed manual for gasoline engines, a standard 6 speed for diesel engines, an optional 4R100 4-speed automatic for gas or diesel, and a 5-speed automatic for the 6.0 diesels. Trucks with the TorqShift 5-speed automatic are rated at exactly 1,000 lb (450 kg) higher towing capacity than trucks with the standard 6-speed manual transmission.

Torqshift 5R110

The Torqshift 5-speed 5R110 automatic transmission replaced the 4-speed in the 2003 model year truck with 6.0 L diesel engine. The TorqShift design in fact has six forward ratios, but only five are advertised, with the 'hidden' gear only used in extreme cold weather. The TorqShift 1st to 5th gear ratios are 3.11, 2.22, 1.55, 1.00, and 0.71:1. It also utilizes an alternate 4th gear, overdrive on 2nd gear of the 3 speed automatic component (0.72 x 1.55), that is 1.10:1 that is used under cold start conditions to aid engine and transmission warm up. On the TorqShift, once the Tow/Haul mode is activated it can help increase a driver's control when towing large loads up and down steep grades and automatically minimizes shifts and maximizes available torque. Upon descent, the Tow/Haul mode utilizes engine braking to help extend brake life and improve driver control. An adaptive shift function monitors the TorqShift's performance over its lifetime, and adjusts shift pressures in real time to assure consistent shift feel and compensate for wear. For ease of maintenance, the TorqShift's oil filter is a spin-off style, mounted on the passenger-side exterior of the transmission. Also the TorqShift's larger fluid lines and a larger transmission oil cooler help to assure cooler operating temperatures, even under the most demanding conditions.

4R100

Gear	1	2	3	4	R
Ratio	2.71:1	1.54:1	1:1	0.71:1	2.88:1

5R110

Gear	1	2	3	4	5	R
Ratio	3.11:1	2.22:1	1.55	1:1	0.71:1	2.88:1

5 Speed Manual

Gear	1	2	3	4	5	R
Ratio	5.72:1	2.94:1	1.61	1:1	0.76:1	5.24:1

ZF S6-650 transmission

Gear	L	1	2	3	4	5	R
Ratio	5.79:1	3.30:1	2.10	1.30	1:1	0.72:1	5.24:1

Transfer case and 4x4

On 4x4 models there still is a choice of a New process(pre 99 250 and 350 used the Borg Warner 1356) manual chain-driven transfer case floor shifter with manual front locking hubs or Electronic-Shift-On-the-Fly (ESOF, a $185 option over the manual) dash knob with vacuum activated automatic and (in case of failure) manual override front hubs. The optional FX4 models are basically a standard 4x4 with an Off Road package that includes a few extras like upgraded heavy duty Rancho shocks, limited-slip rear differential, added skid plates for the fuel tank and transfer case, and two "FX4" decals on both back bed-sides instead of the standard "4x4". For all 4x4 models, the 2-speed transfer case 4x4-LOW range has a gear reduction of 2.72:1. The 2005 F-250 Super Duty has an unusually large number of Complaints referring to a "Death Wobble" in the front suspension. An investigation has pointed out that tire pressure is very critical although many complaints have posted that correct tire pressure was maintained. Aftermarket track bar kits can mitigate these effects and improve the ride.

Front suspension

The front suspension on 4x4's use a solid front (monobeam) Dana 50 and Dana 60 axles on the F-250 and F-350 pickups. A Dana 60 is used on the F-450 and F-550's until the 2005. The 2005-2007 models use a Dana Super 60. Leaf springs eventually got switched to coils and a sway bar was added. The front suspension on 4x2 models is independent twin I-beam with coil springs on the F-250 and F-350 pickups. While a solid axle is used on F-450 and F-550 trucks. The manual locking hubs on Super Duty trucks are made by Warn

F-250 solid axle

The Dana 50 axle featured on most F-250 Super Dutys differs greatly from the early models. The Dana 50 started out as a Twin Traction Beam axle (much like Independent suspension ) in 1980. This lasted all the way to 1997 models. The Super Duty models then used a solid axle version of this axle. The ring, pinion, carrier and u joints all remained the same however.

Rear suspension

The rear suspension on all F-250 models and SRW (single rear wheel) F-350 models use a 10.5-inch (270 mm) Sterling 10.5 axle 35-spline axle with choices of conventional or limited-slip differentials in 3.73, 4.10, and 4.30:1 ratios. The Sterling axle was upgraded for the Super Duty trucks. The ring gear was increased from the 10.25 inches to 10.50 and the carrier was upgraded with three pinions instead of two. While the DRW F-350 models use a Dana 80. All models have heavy duty 3" wide leaf springs and staggered shock absorbers. A standard stabilizer bar is included on DRW models. An optional slide-in camper certification package with heavier springs and an optional stabilizer bar package are available on SRW models. The rear suspension on F-450 trucks used Dana 80 axles while F-550 models used a Dana 135 until 2005 models. 2005-2007 models use a Dana S 110 axle.

Ford F-350 Dually
Ford F-550 crew cab pick up
1999–2004 Ford F-550 cutaway

Facelift (2005–2007)

2005–2007 Ford F-350 King Ranch crew cab

The Super Duty line was restyled for 2005. Exterior and interior styling were given minor updates(dash,gauges,front grille and headlights, badges), however, with this facelift came significant changes both in mechanics and options offered.

Major changes over the previous generation of Super Duties include increased payload (GVWR) and towing (GCWR) capacities, a new taller front grille, revised interior, standard locking tailgate, 10-17% thicker partially boxed frame, alternator with a higher current capacity, larger-than-before 4-wheel disc brakes (13.66-in front and 13.39 in (340 mm) rear rotors) with new two-piston calipers, revised engines, new automatic transmission options, a new optional built-into-dash Ford TowCommand TBC (Trailer Brake Controller) that is fully integrated with the truck's PCM (Powertrain Control Module) and ABS (Anti-lock Braking System), optional dashboard-integrated auxiliary "upfitter" switches (for adding off road lights, winches, snow plows, etc.), and an optional drivers side glove compartment.

The two previous gas engines were upgraded from 2 valve per cylinder to 3 valve (2 intake and 1 exhaust) per cylinder designs. The standard 5.4 L V8 produces 300 horsepower (220 kW) and 365 foot-pounds force (495 N·m) of torque, and the optional 6.8 L V10 produces 362 hp (270 kW) and 457 ft·lbf (620 N·m).

Ford's "Fail-Safe Cooling System" is designed to protect the engine due to loss of coolant. If the engine overheats, it will automatically switch from 8/10 cylinder (depending on V8 or V10 engine) operation to alternating 4/5 cylinder (depending on V8 or V10 engine) operation. Because there is now 50% less hot combustion, the engine will operate cooler. The vehicle will continue to operate, but with very limited engine power. The now so-called 'dead' cylinders also act like an air pump to cool the engine down even more. This system allows the driver to travel a short distance to obtain service or to reach a repair facility. The distance that can be traveled depends upon vehicle load, outside temperature, and current road conditions.

Two transmissions were made available for the redesigned 2005-2007 models. The standard M6OD 6-speed manual overdrive and the optional heavy duty TorqShift 5R110W 5-speed automatic overdrive with Tow/Haul mode which replaced the 4-speed 4R100 used in the first generation.

Ford offers a PTO (power take-off) which provides direct engine power for accessory equipment without the expense and installation time of separate, independently mounted electric motors or other power sources. The standard equipment 6-speed manual transmission comes with an integrated PTO. The optional TorqShift 5-speed automatic transmission can be equipped with an integrated PTO provision (which automatically locks the torque converter providing power to the PTO gear when the operator turns on the PTO switch).

Fuel tank capacities are 38 U.S. gallons in the 8' long bed models, and 29 U.S. gallons in the 6.75' short bed models. Depending on models the optional trailer tow hitch receiver comes with a 2" or 2.5" Class V receiver and 4- and/or 7-pin wiring harness in either 12,500 or 15,000 lb (6,800 kg). All Super Duties include factory installed external oil and transmission coolers. Depending on model and options, the empty title curb weight is 6,000-8,000 lb.

Second generation (2008–2010)

Second generation

Also called	F-250 F-350 F-450 F-550
Model years	2008–2010
Assembly	Louisville, Kentucky, United States Escobedo, Nuevo León, Mexico Valencia, Carabobo, Venezuela
Engine	5.4 L Triton V8 (2008-10) 6.8 L Triton V10 6.4 L Power Stroke diesel V8 (2008-10) 6.2 L "Boss" V8 (2011+) 6.4 L Power Stroke diesel V8 (2011+)
Transmission	ZF S6-650 6-speed manual 5-speed 5R110W automatic 6-speed 6R140 automatic
Wheelbase	137 in (3,480 mm) 141.8 in (3,602 mm) 158 in (4,013 mm) 156.2 in (3,967 mm) 172.4 in (4,379 mm)
Length	227 in (5,766 mm) 231.8 in (5,888 mm) 248 in (6,299 mm) 246.2 in (6,253 mm) 262.4 in (6,665 mm) 271.5 in (6,896 mm) (F-450, F-550 SuperCab) 274.5 in (6,972 mm) (F-450, F-550 Regular Cab) 285.9 in (7,262 mm) (F-450, F-550 Crew Cab) 286.5 in (7,277 mm) (F-450, F-550 Regular Cab) 381 in (9,677 mm) (F-650 Kick-Up Frame, Regular Cab) 359 in (9,119 mm) (F-650 Kick-Up Frame, SuperCab) 399 in (10,135 mm) (F-650 Kick-Up Frame, Crew Cab) 440 in (11,176 mm) (F-650 Straight Frame, F-750 Regular Cab) 440 in (11,176 mm) (F-650 Straight Frame, F-750 SuperCab ) 417 in (10,592 mm) (F-650 Straight Frame, Crew Cab) 392 in (9,957 mm) (F-750, Crew Cab)
Width	79.9 in (2,029 mm) 95.5 in (2,426 mm)
Height	76 in (1,930 mm) – 81 in (2,057 mm)

The second-generation Super Duty was to debut for 2007, but quality issues pushed it back to a 2008 model. The new 2008 model features an all-new 6.4 L (6400 cc, 390.5 cu in) twin-turbo Power Stroke Diesel V8 with piezo fuel injectors to replace the problematic 6.0 L Power Stroke single-turbo Diesel V8. The new engine is said to produce 350 hp (260 kW) and 650 ft·lbf (880 N·m) of torque. The vehicle had its first official showing at the Texas State Fair in 2006.

Located near the same dash area as the last generation (but slightly to the right and more directly below the radio), this generation of Super Duty has the same Ford TowCommand TBC (Trailer Brake Controller) and 4 AUX Upfitter switches as the last generation set-up.

There is an optional concealed slide-out step and swing-up hand grab bar in the rear tailgate for easy access.

Ford introduces its all new optional "Rapid-Heat Supplemental Cab Heater," only available on Super Duty trucks with the Diesel engine and TorqShift automatic transmission. In the winter, it quickly raises the cabin temperature to a comfortable level until the engine is warm enough to handle the job.

The 2010 Super Duty was awarded 'Best Resale Value Truck".

Trim levels

This 2nd generation of Super Duty includes the F-250 Super Duty (starting at $22,380), F-350 Super Duty (starting at $24,025), and the all new F-450 Super Duty (starting at $39,205). The F-250 and F-350 Super Duty basically has the same payload and towing specs as the last generation.

The model lineup for the 2010 F-250 and F-350 Super Duty is the XL (starting at $25,300), XLT (starting at $28,845), Lariat (starting at $36,420), Cabela's (starting at $42,655), King Ranch (starting at $42,955), and Harley-Davidson (starting at $56,925).

The model lineup for the F-450 Super Duty is the XL (starting at $44,145), XLT (starting at $49,525), Lariat (starting at $52,965), King Ranch (starting at $56.955), and the Harley Davidson (starting at $62,625)

The FX4 model, which was once just an optional Off Road 4x4 package that could be added to any model in the lineup, is replaced by the 4x4 Off Road Package. The FX4 became a model of its own. It still had the same specs as the previous generation but with more of a sporty trim package. The FX4 model has been discontinued for the 2010 model year and has been reverted to an optional Off Road 4X4 package.