FORD SUPER DUTY DESIGN DRAWS INSPIRATION FROM ‘MIGHTY F-350 TONKA’ CONCEPT

The 2005 Super Duty’s appearance – inspired by the popular ‘Mighty F-350 TONKA’ concept truck – caps off the host of improvements under the skin. The new exterior look projects more confidence than ever, with a bolder grille and bigger wheels leading the way, while more subtle changes to the interior and exterior refine the design theme.

“Even a hard-working truck should clean-up well,” said Gordon Platto, chief designer.

Taking both of those concepts – confidence and refinement – to extremes is the new Ford Harley-Davidson™ F-Series Super Duty, with three appearance options including a bold new factory-painted flame that uses a show-quality wet-on-wet process.

Highlights of design changes for 2005 include:

• Interior – The instrument panel is more refined and modern, with appliques that match the door panels. The industry’s first factory-installed optional trailer brake controller and upfitter switches are integrated into the instrument panel. The message center moves to the gauge cluster, as in other Ford vehicles.
• Exterior – The new, larger dominant grille takes its cue from the Mighty F-350 TONKA concept, with horizontal bars that appear to have been milled from a block of steel, and a centered nine-inch Ford blue oval. The bumpers have been refined to match the lowered “waterline” of two-tone trucks. New jeweled headlamps modernize the front profile.
• Ford Harley-Davidson™ F-Series Super Duty – The 2005 Harley-Davidson™ Super Duty has special touches that cement the bonds between Harley enthusiasts and their machines, such as stitched leather-trimmed seats. The wet-on-wet paint process for the “flame” trucks, available later in the model year, does full justice to the customizer’s art.

The most dominant exterior feature of any Super Duty truck is the bold, imposing grille. For 2005, that statement gets even bolder, with more height, more presence and a more machined appearance.

The new grille owes its inspiration to the “Mighty F-350 TONKA” concept, which was unveiled at the 2002 North American International Auto Show in Detroit. At the time, Ford Group Vice President of Design J Mays hinted “someday you might see a truck like this in your driveway.”

Design changes to the 2005 Super Duty are carefully targeted toward the areas customers will notice and appreciate most – such as the grille.

“The horizontal bars of the new grille are designed to appear as though they were machined from billet steel,” Platto said. “We were able to make the grille larger by extending the bottom of the grille and nesting it within the bumper fascia, rather than sitting on top of the bumper. This allowed us to enlarge the proportion of the grille to make it the dominant focal point of the front end.”

The grille retains the Ford Tough Trucks “nostrils” that flank the horizontal bars. A large blue Ford oval is centered in the grille. The large spaces, with honeycomb mesh between the chrome bars provide detail and help to reinforce the sense of strength and power of the engines beneath the hood.

Larger Wheels – Up to 20 Inches

New forged wheels also make a statement of strength on the 2005 Super Duty. The standard wheel size grows an inch to 17 inches, while 18-inch wheels are available on several models. All of the wheel designs are new, with new center caps.

“You look for strength in a wheel – both visually and to handle the load,” Platto said. “That’s why you’ll see a lot more surface area on some of the wheels, to communicate that strength. We went for a machined look to harmonize with the grille. The new wheels look very structural.”

Super Duty customers will find a lot more selection, particularly in the 18-inch size, with a choice of 14 different steel, chrome and forged aluminum designs.

The Ford Harley-Davidson™ Super Duty breaks new ground by offering the first 20-inch wheels in the heavy duty pickup segment.

But the 2005 Super Duty design is not just about boldness – it’s about refinement. That’s apparent in the new, jeweled headlamps and turn signals. The lamps are stacked vertically, with complex reflectors. The new turn signal treatment uses a clear lens and amber bulb.

Another design refinement that traces its roots to Ford’s “Mighty F-350 TONKA” is the new bumper treatment.

“We reversed things – we now have a chrome steel lower bumper, with a painted upper fascia,” Platto said. “This helps to establish a lower ‘waterline’ and allows us to align with the two-tone pattern on the Lariat and King Ranch models. It’s a cleaner, more refined look.”

The lowered waterline and revised two-tone treatment are carried through to the rear bumper. New two-tone color combinations on the Lariat trucks include Arizona Beige paired with Dark Stone, Dark Copper or Dark Green Satin.

Wheel lip moldings are used to provide series differentiation. Optional 5-inch polished tubular step bars or running boards, depending on model, help to ease entry and exit. Optional reverse sensors assist with parking.

Larger three-dimensional series badges on the vehicle sides identify the series. The V-8, V-10 and Power Stroke Turbo Diesel badges are larger and more prominent, as well.

Interior Proves Toughness Can Be Comfortable

Changes to Super Duty’s interior design concentrate on the areas where customers will benefit most – especially the driver’s “working environment.”

“The interior is much richer,” Platto said. “All of the elements work well together, and we were able to create more series differentiation.”

That’s important to satisfy the growing number of customers who buy Super Duty trucks for personal use. This part of the market has grown dramatically since 1994 – reflected in the increasing popularity of Crew Cab trucks, which have seen nearly 70-percent growth in share of sales in the past 10 years. Sales of the Lariat series have grown more than 50 percent since 1998.

For 2005, new accent trim panels surround the central and driver’s side portions of the instrument panel and match the inserts on the doors. King Ranch and Lariat trucks are available with unique wood-grain appliques. King Ranch sports a straight-grained Dark Mandarin Teak pattern, while a warmer Cherry Zebrano grain is used on Lariat.

A more technical, fine-patterned surface appearance is used on XLT, while XLT Sport trucks use a pewter metallic finish.

A new gauge cluster is cleaner and easier to read, with the circular vehicle speed and engine speed gauges flanking the message center and gear selector display. Modular design allows more differentiation in the gauge package.

“The gauges are an important element of creating the interior environment,” Platto said. “This area is right in the driver’s line of sight, whenever they are in the vehicle. It has to be a high priority.”

The new dual-zone climate control system features barrel-shaped vents with contours that match the instrument panel face. More controls, such as speed, audio and climate control buttons, are right at the driver’s fingertips on the steering wheel spokes on selected series. A power sliding rear window is offered on XLT and Lariat.

Super Duty offers more interior space than any other pickup. Front seats are available with a split 40/20/40 bench that offers a fold-down center armrest with storage bin and two cup holders. On King Ranch trucks, a fixed center console features an armrest wrapped in distinctive Castaño leather, to match the steering wheel, seats and leather-wrapped grab handles on the A-pillars.

The King Ranch logo appears on the armrest, instrument panel and floor mats.

The Flex Fold rear seats offer convenient interior cargo options. The split-fold rear seats, introduced in the 2004 model year, allow the user to fold down one or both seatbacks to create a flat shelf, or fold the seat bottoms up to create more floor space. Another convenience feature introduced in 2004 allows the rear doors of Crew Cab models to swing open 5 degrees farther than previously, for better access to the rear seating area.

Designed for Commercial Users

Adding to the clean interior appearance, the optional four upfitter switches and integrated trailer brake controller are flush-mounted into the instrument panel. These switches are used by upfitters, who add accessories such as light bars, dump bodies, cargo boxes or tow equipment onto the Super Duty chassis.

They are a marked difference from Super Duty's competitors – where these elements have had a “tacked on” appearance, as aftermarket installers are forced to locate these switches beneath the dash.

It also assures that these key controls are within easy reach of the driver, with placement and operation confirmed by Ford’s ergonomics engineers.

Ford Harley-Davidson™ Super Duty Has True Custom Feel

For 2005, the Ford Harley-Davidson™ F-Series Super Duty kicks it up a notch, with two bold new optional flame paint jobs – the first factory-painted flame trucks in the industry – and a host of distinctive comfort and appearance features.

“These are truly custom vehicles and the biggest, baddest, boldest trucks out there,” said Platto.

The custom appearance starts up front, with a unique black-and-chrome billet-like grille and blacked-out headlamps. Chrome tow hooks and fog lamps add pinpoints of light, particularly evident on black trucks.

The bright-polished forged aluminum wheels – now at a 20-inch size that is another first for the segment – feature dimples around the rim, precisely milled spokes and distinctive “Harley-Davidson” script on center caps that show off the locking chrome lug nuts. Between the wheel wells, a tubular chrome step bar with the Harley-Davidson Bar & Shield logo now features a black-out backer for a cleaner, more integrated appearance.

The distinctive custom flames – in Toreador Red on black, or True Blue with Medium Wedgwood Blue – use Ford’s patented new wet-on-wet paint process to produce factory-painted graphics that are as smooth and seamless as those applied in a custom motorcycle shop.

Ford’s production team knew right away that this process would open up exciting new possibilities, especially for the Harley-Davidson™ Ford Super Duty.

Willie G. Davidson, Harley-Davidson Senior Vice President of Styling and Chief Styling Officer; Louie Netz, Vice President - Director of Styling; and Ray Drea, Styling Manager, came to the Ford Design Studios in Dearborn to see the new Super Duty and review an early concept with Platto.

They studied the truck, discussed flame philosophy, then Drea pulled a China marker from his pocket and drew the flame pattern right on the sheet metal. Digitized templates were pulled directly from his flowing lines.

Industry-Leading Wet-On-Wet Paint

In the wet-on-wet paint process, a special primer allows a second coat of paint to be applied while the first layer is still wet. In the case of the black flamed truck, the Toreador Red layer is painted first, across the lower half of the truck.

An ultra-thin mask in the shape of the flame pattern is applied over this red paint, and the black topcoat is sprayed immediately. The thin mask is pulled off, a clear topcoat is sprayed on, and chemical bonding between the layers produces a smooth, durable, seamless finish.

The standard Ford Harley-Davidson™ Super Duty package pairs black exterior paint with a thin, competition-orange tape stripe that extends fully around the vehicle. Heavyweight zinc die-cast metal badges celebrate the Ford Harley-Davidson Alliance, and a large Harley-Davidson Bar & Shield logo marks the standard rubber bed mat.

Chrome tie-down hooks and a bullet-style welded-on chrome exhaust tip, with dimples to match the wheel design, provide bright relief at the rear of the vehicle.

New Two-Tone Leather Seating

All Ford Harley-Davidson™ Super Duty trucks sport a distinctive interior, with stitched two-tone black leather trimmed seats bearing the Harley-Davidson Bar & Shield logo. Interior door panels are Dark Flint – darker than the standard Super Duty interior, to create a warm persona.

The door inserts and instrument panel applique feature a technical pattern that resembles carbon fiber – until you look very closely and see the hundreds of tiny Harley-Davidson Bar & Shield logos.

The unique gauge cluster features twin chrome-ringed instruments with spun-metal faces and a contoured chrome “bridge” joining them. Most touchpoints, including the power seat controls, are chromed. Brake and accelerator pedals resemble the chrome-and-black footboards of a custom big V-twin cruiser. The ignition key has a Harley-Davidson Bar & Shield logo on one side and a Ford oval on the other.

The truck features a serialized nickel plate atop the black-leather-wrapped center console, showing the truck’s production date and number. Rear seats are available as a bench or captain’s chairs with center console.

The 2005 Ford Harley-Davidson™ Super Duty is available in F-250 and F-350 4x4 configuration with either the 6.0-liter Power Stroke diesel or 6.8-liter Triton V-10 engine. Production begins in the fourth quarter of this year.

Limited-Edition Amarillo Super Duty Blazes New Trail

The new F-Series Super Duty is no shrinking violet – especially not when it’s painted Blazing Yellow.

The bold, distinctive yellow monochromatic paint scheme identifies the Super Duty Amarillo – a limited-edition pickup to be sold in the Southwest, Denver and California markets.

Amarillo was inspired by the Mighty F-350 TONKA concept vehicle, which likewise featured a bright yellow exterior.

“We thought that since the 2005 Super Duty uses Mighty TONKA design cues, we could create more buzz with a limited-edition production truck that captures more of that excitement,” said Phil O’Connor, F-Series Super Duty marketing manager.

“It will certainly generate excitement on the showroom floor and call attention to the fact we have a new Super Duty this year,” he said.

The Amarillo package, available on diesel-powered F-250 and F-350 XLT SuperCab and Crew Cab pickups, features:

• Monochromatic Blazing Yellow exterior, including door handles and body-color moldings.
• Chrome bumpers with fog lamps, and chrome tow hooks, tubular step bars and muffler tip.
• Black interior, with black leather-wrapped steering wheel, black leather seating surfaces on the front captain’s chairs and rear bench, black carpet, ebony and platinum-colored trim.
• Four-wheel-drive with LT275/70R18 outline-white-letter all-terrain tires on 18-inch forged aluminum wheels.
• Options include the reverse sensing system and roof marker lights.

2005 FORD SUPER DUTY PUSHES THE ENVELOPE OF PICKUP TRUCK PERFORMANCE

For 2005, Ford has made the best even better, improving the capability of Super Duty in every key measure – towing, hauling, power, ride and handling – to again set new standards for the class.

“Capability is the heart of a pickup truck – and the soul of the Ford Super Duty,” said Frank Davis, Ford vehicle programs director for pickups and commercial vehicles.

Towing is central to most Super Duty customers – 90 percent of them tow. But capability is measured in more than raw numbers. Capability is about the ability to use all of a truck’s capacity in the real world – and to want to use it again and again.

“That’s the kind of thinking that went into the development of Ford’s exclusive new TowCommand System,” said F-Series Super Duty chief engineer Susan Dehne.

This package of features and capabilities was designed by professionals who tow and haul heavy loads, leveraging new technology and smart engineering. The all-new TowCommand System includes:

• Integrated trailer brake controller – an industry first, the electronic trailer brake controller is fully integrated into the vehicle’s braking system. This means it can better infer drive intent for unprecedented smoothness – and it is the only trailer brake controller that can adapt its operation based on information from the tow vehicle’s anti-lock braking system. It’s also the only factory-installed and warranted electronic trailer brake controller on the market.
• TorqShift automatic transmission with tow-haul mode – Ford’s advanced TorqShift transmission, now available on all Super Duty gas and diesel engines, offers a shift strategy specially designed for towing and hauling heavy loads. On downhill stretches, the transmission and engine work together to help control vehicle speed.
• Adjustable trailer towing mirrors – Super Duty’s distinctive, user-friendly towing mirrors offer a large viewing area, convex mirrors on both sides and a telescoping feature allowing the mirrors to be adjusted outward to see beyond wide trailers. The mirrors are heated and power-adjustable with an integrated turn signal.
• Best-in-class braking – Super Duty’s braking system is upgraded in nearly every way, to offer confident stopping power or to hold a heavy load stationary on an incline, using the parking brake.

Class-Leading Tow Rating

If there’s one number that defines the hierarchy in this class, it’s the tow rating. This represents the heaviest trailer that a vehicle is rated to tow, with proper equipment. Ford Super Duty leads in nearly every category – with four-wheel or two-wheel-drive, conventional or fifth-wheel towing.

The 2005 Ford F-350 has the ability to tow up to 17,000 pounds with a fifth-wheel hitch. Conventional tow rating also tops the class at up to 15,000 pounds. Either way the F-350 is the most capable tow vehicle in the class.

Industry-First Trailer Brake Controller

The marquee player in Ford’s optional new TowCommand System is the new industry-first integrated trailer brake controller, which offers these game-changing features:

• Smooth, intuitive braking feel, with the trailer’s brakes and the Super Duty’s brakes working at the same rate.
• Safety features include audible and visual warnings. The message center in the Super Duty’s gauge cluster alerts the driver to any malfunctions, including if the trailer wiring becomes disconnected.
• Ability to draw information from the vehicle’s anti-lock braking system (ABS), engaging a different trailer braking strategy during vehicle ABS operation for improved control.
• Superior ergonomics, with an integrated appearance, intuitive controls, visual confirmation that the trailer wiring is properly connected and graphic display of braking force.
• Ford factory installation and warranty protection.

Towing enthusiasts have long relied on aftermarket controllers to help them take advantage of the electric brakes on their trailers and campers. In fact, Ford market research shows 80 percent of Super Duty owners currently install aftermarket trailer brake controllers.

But these aftermarket units bring compromises. For example, their braking performance can be harsh or jerky, particularly at slow speeds. When they send power to the trailer brakes, which are activated electrically, it can be like a light switch – full power, or none at all.

Some aftermarket brake controllers use mechanical devices, such as internal pendulums or inertial sensors, to try to infer driver intent. Others introduce an automatic lag into the brake force buildup, to reduce that “light switch effect.” But all of those approaches are compromises, meant to reduce objectionable results while allowing full brake force when needed.

Integrated Design Offers Advantages

Most aftermarket braking controllers look like afterthoughts – they are typically mounted to the lower dash panel with brackets and screws, trailing a pigtail of wiring.

With its trailer brake controller, Ford changes the game by integrating the trailer brake control features into a convenient in-dash unit. The controller uses actual braking pressure, measured inside the vehicle’s master cylinder, to know how much braking force the driver means to apply. It can modulate the trailer brakes in real time.

Because the controller is integrated, it is the first trailer brake controller to adapt its output based on the state of the vehicle’s anti-lock braking system (ABS).

“We’re constantly getting information from the ABS module and from the powertrain controller on the high-speed network,” said Doug Marsden, Ford supervisor of Advanced Brake Controls.

“We alter our control strategy when the ABS senses that the tow vehicle’s wheels are slipping, so the trailer wheels are less likely to lock up,” Marsden said. “We also adapt trailer braking based on vehicle speed – no aftermarket controller knows the tow vehicle’s speed.”

Following a simple, intuitive adjustment by the driver to account for the trailer weight and road conditions, the trailer brake controller works so seamlessly that it’s possible to forget there’s a heavy load on board. The trailer’s brakes work at the same rate as the Super Duty brakes, for smooth, assured stopping.

Operation is Speed-Sensitive

In stop-and-go city driving – where many drivers simply turn off their conventional trailer brakes in frustration due to uncomfortable lurching and grabbing – Super Duty’s integrated brake controller really shines. By automatically reducing brake force at lower speeds and lower brake pedal pressures, this system lets the driver creep forward in traffic, stop smoothly at intersections and maneuver easily in parking lots – all with smooth, seamless braking.

At higher speeds, more aggressive trailer braking is possible without driver adjustment. This assures short stopping distances. Customers will not have to continuously adjust the controller depending on whether they are on the highway or in the campground.

For the first time, not only does the new trailer brake controller let the driver easily and naturally modulate the trailer brakes, it actually looks like it belongs – integrated into the dashboard within the driver’s reach, with clear, matching graphics and a dimmer function linked to the other instrument panel lights.

Display Presents Information at a Glance

The front panel shows a simple graphic to confirm that trailer wiring is properly connected, and shows the amount of force being sent to the trailer as the brakes are applied. Because the controller is wired into the vehicle’s electronics, it can send important information to the message center in the gauge cluster.

The controller’s location and design were developed and confirmed using Ford’s ergonomics programs as well as extensive field testing – another advantage over aftermarket units.

“The Super Duty was already the best tow vehicle – this just makes it better,” said Harry Rawlins, 4x4 and trailer tow engineer, and one of Ford’s in-house towing experts.

Ford Team Fine-Tunes Towing Capability

Rawlins, a Texan who has towed everything from construction equipment to prized longhorn bulls, was a member of Ford’s team of experts in evaluating the best – and worst – features of competitive tow vehicles and brake controllers.

This kind of institutional knowledge is critical for a vehicle like Super Duty that has to function as an extension of the driver – like a hammer for a carpenter. For example, the Super Duty towing mirrors, which pull outward for a better rearward view around wide trailers, have been a big hit with consumers.

“People really appreciate the towing mirrors,” Rawlins said. “If you’ve ever towed with little mirrors, you understand!”

There’s a tendency to think of heavy trailers and big RV campers as being towed only via fifth-wheel or gooseneck hitches. But that’s not always the case. Approximately 60 percent of Super Duty customers who tow – both retail and commercial users – use a conventional hitch.

Those customers will appreciate another new Super Duty feature – a factory-installed 2.5-inch receiver, optional with dual-rear-wheel F-350 trucks equipped with the 6.0-liter Power Stroke diesel or 6.8-liter Triton V-10 gasoline engine.

The bigger draw bar – up from the previous 2-inch receiver – allows towing conventional trailers up to 15,000 pounds.

“We’re including an adapter that takes the receiver down to 2 inches if desired, so our customers can still use their current towing equipment,” Rawlins said.

TorqShift, Tow-Haul Mode Available With All Engines

Expanded availability of Ford’s TorqShift automatic transmission brings the convenience of tow-haul mode to all Super Duty models that are equipped with automatic transmissions. This feature, previously available only with Power Stroke diesel engines, adjusts transmission response to improve performance on both acceleration and deceleration.

On downhill stretches, the transmission and engine work together to help keep the vehicle from gaining speed. This enhances the driver’s feeling of control, especially when the vehicle is heavily loaded or towing a large trailer. It also helps to reduce brake wear.

Uphill, the transmission will hold a gear longer when in tow-haul mode, to reduce the “hunting” effect that can occur when cresting one rise, only to encounter another. The engine remains in its power band. Both gasoline engines – the new 5.4- liter, 3-valve Triton V-8 and new 6.8-liter, 3-valve Triton V-10 – are now rated to higher RPM, to take advantage of this feature of tow-haul mode.

Another significant advantage of bringing the five-speed TorqShift automatic transmission to the gasoline engine family is the wider overall ratio spread of its gearing. A higher first gear improves launch performance from a dead stop.

“Competitive vehicles that brag about their 0-60 mph times are going to find themselves staring at the Super Duty tailgate,” Dehne said.

New Suspension Enhances Towing

The final major contributors to Super Duty’s class-leading towing capability are the all-new front suspension geometry that provides better steering feel and response, as well as brake system improvements for class-leading braking.

The new suspension design improves lateral stability – especially noticeable in cross-winds or quick lane-changes – and reduces steering efforts. The new monobeam, coil-spring front suspension on F-250 and F-350 4x4 trucks dramatically reduces the turning circle, while offering superior ride and comfort.

“Going from a leaf spring to a link-coil front suspension gives us several advantages, including increased roll stiffness and the ability to fine-tune the ride,” said Pete Reyes, F-Series Super Duty vehicle engineering manager. “We can handle a load better, and that’s very important for our customers.”

The front radius arms on 4x4 vehicles also act as “anti-windup” bars, improving traction and reducing the chance of wheel-hop under hard acceleration. The front suspension on two-wheel-drive pickups is unchanged.

The rear suspension has been improved, as well, with new spring rates and new staggered rear shock geometry to improve ride quality. Rear gross axle weight rating for the F-350 dually is increased from 8,250 to 9,000 pounds.

Uprated Axles Assist Plowing

One scenario that points up the improvements of four-wheel-drive F-250 and F-350 pickups is their ability to handle the load of a front snowplow.

Over rolling surfaces, the reduction in vehicle pitch and roll keeps the plow blade under control, whether it’s in the raised or lowered position. Some competitive trucks allow so much front-rear pitch that a front-mounted snowplow can contact the ground unintentionally during highway driving.

For the first time, a factory-installed snowplow prep package will be offered on two-wheel-drive versions of the F-450 and F-550 chassis cabs. Snowplow prep also is offered on more pickups, and larger size snowplows can now be installed thanks to upgraded front axle weight ratings – 6,000 pounds on F-250 and F-350 and 7,000 pounds on F-450 and F-550.

With the monobeam and coil-spring replacing the leaf spring suspension, 4x4 F-250 and F-350 owners now can turn their front wheels 18 percent farther in either direction, which dramatically improves maneuverability and reduces the average turning circle by more than 5.5 feet.

Improved Ride and Handling

Scrub radius – a key measure that affects how force is transmitted to and from the front wheels – was reduced by moving the steering pivot point farther outboard on 4x4 vehicles, creating a 51-percent improvement. This design offers better steering feel and more resistance to “pull” and bump steer from road irregularities or uneven crowning. Parking efforts are improved by 45 percent on 4x4 trucks.

Changes to the steering geometry and tighter tolerances in the steering gear improve response, while new internal valving improves steering feel. The F-450 and F-550 Super Duty chassis cabs get variable assist steering to go with more than a 12-foot improvement in average turning circle.

“It’s all about capability,” Reyes said. “With these improvements, our trucks will ride and handle as well as anything on the market – but with a larger payload.”

Tires play an important part in ride and handling, as well as load-carrying capability. New for 2005, Super Duty comes standard with 17-inch wheels, with 18-inch wheels available on several models. The 2005 Ford Harley-Davidson™ F-Series Super Duty will feature 20-inch wheels – the first time this wheel size has been offered in this class.

Tire construction and tread pattern have been customized to work with the Super Duty improvements, including its more powerful brakes.

Larger Brakes Inspire Confidence

For 2005 Super Duty braking is improved for increased performance, usability and durability.

Key durability improvements include up to 50 percent more brake lining life on single-rear-wheel models and double the life on dual-rear-wheel trucks.

That’s a significant customer benefit – and one that really adds up for fleet owners.

Braking engineers took advantage of the larger standard wheel sizes to increase the size of the truck’s brake rotors by approximately 5 percent, to 347 mm in front and 340 mm rear. This provides greater swept area for maximum braking and helps to dissipate heat, especially on long, steep downhill roads.

Other improvements include larger calipers for both F-250 and F-350. The front calipers have twin 60 mm pistons – up 11 percent from the previous model – and are 30 percent stiffer for better braking feel. Rear calipers have twin 48 mm calipers on F-250 and twin 54 mm pistons on F-350 models. Chassis cab models also benefit from stiffer calipers and larger brake rotors.

The larger parking brake for F-250 and F-350 models allowed an increase of over 15 percent in its maximum load rating. The hydraulic master cylinder also has been upsized, with a new boost assist curve, for better brake pedal feel. New brake pad material provides quieter stops while more than doubling lining life.

The calipers are rear-mounted for protection, taking into account the rough environment in which many Super Duty trucks live. Brake lines are nylon-coated for durability.

Better Pedal Feel

The day-to-day consumer benefits from braking system improvements include an enhanced pedal feel and more intuitive brake response. Changes to the suspension and steering geometry complement the braking system upgrades by reducing “pull” under braking when the tires have differing traction. Available adjustable pedals also enhance the interface between the driver and braking system.

“We’ve really moved the needle on pedal feel,” said Hal Felch, braking supervisor. “There’s a lot more modulation – you really feel the stopping power. Even at the increased gross vehicle weight rating, with a full load of cargo, you’ll notice a strong, confident brake feel.”

Super Duty also benefits from a next-generation ABS system, using the vehicle’s high-speed data network. New wheel sensors provide more information, more quickly, by processing data internally before sending the information to the central ABS computer.

“That’s consistent with all of the Super Duty improvements,” Felch said. “We have increased the overall capacity while improving the customer experience. The best has gotten better.”