Ford Super Duty

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See also Ford Super Duty engine for the 401, 477, and 534 engines built from 1958 to 1981.
Ford Super Duty
3rd-gen Ford F-450 crew cab
Automotive industryFord Motor Company
PredecessorFord F-250/350
Car classificationFull-size Pickup truck
Automobile layoutFront-engine design, Rear-wheel drive / Four-wheel drive

The Ford Super Duty is a line of commercial 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 Assembly in Louisville, Kentucky. The F-650 & F-750 Super Duties are assembled at the Blue Diamond Truck plant in Mexico. For Mercosur (Brazil (F-250,F-350 AND F-4000)and Argentina (F-100)) are assembled at the Brazil, Engine 3.9 TurboDiesel, alvailable 4x2, 4x4, single cab w/short bed, crew cab w/short bed, single cab/ crew cab chasis.

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), & F-350 Ford truck lines. In appearance, the Super Duty line might look a little similar to but does not share any of the design or build characteristics of the F-150. A F-250 Super Duty would surpass the older traditional F-350 in most categories.


First generation (1999-2004)

First Generation
Ford F-350 Dually
Also calledF-250
Model year1999-2004
AssemblyLouisville, Kentucky, USA
Silao, Mexico
Sao Bernardo do Campo, Brazil
Internal combustion engine5.4 L Modular V8
6.8 L Modular V10 engine
7.3 L Powerstroke Diesel V8
6.0 L Powerstroke Diesel V8
Transmission (mechanics)5-speed manual
4-speed Ford 4R100 transmission automatic
ZF S6-650 transmission
5-speed 5R110W automatic
Wheelbase137 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)
Length222.2 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)
Width79.9 in (2,029 mm)
95.5 in (2,426 mm)
Height76.2 in (1,935 mm) - 81.3 in (2,065 mm)
RelatedFord Excursion
Ford F-350 crew cab

For the 1999 model year, Ford dropped the regular (now to be considered the 'light duty') F-250, F-250HD (Heavy Duty), and F-350 truck lines only to introduce all-new F-250 and F-350 Super Duty trucks. 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, liked the idea so much that for the 2001 model year, the Chevrolet Silverado and GMC Sierra HD were introduced.

The Super Duty had several available engines. A 2-valve per cylinder 5.4 L Modular V8 with 260 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 engine with 310 horsepower (230 kW) and 425 ft·lbf (576 N·m) of Torque was an option. The 7.3 L Power Stroke Turbodiesel with 235 horsepower (175 kW) and 500 foot-pounds force (680 N·m)of torque from 1999 to 2002 and upped to 250 hp (190 kW) and 525 ft·lbf (712 N·m) of torque in 2003. The 6.0 L 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.

Ford F-450 Super Duty

Four Transmission (mechanics) were available. A standard 5-speed manual for gas engines, a standard 6-speed Manual transmission for diesel engines, an optional Ford 4R100 transmission 4-speed automatic for gas or diesel, and an optional 5-speed automatic for Diesels. The 4-speed automatic was replaced in the 2003 model year truck with 6.0L Diesel engine by the new Torqshift 5-speed 5R110 Automatic transmission. The 5-speed manual 1st to 5th gear ratios are 5.72, 2.94, 1.61, 1, & 0.76:1 with Reverse being 5.24:1. The 4-speed auto 1st to 4th gear ratios are 2.71, 1.54, 1, & 0.71:1 with Reverse being 2.88:1. The TorqShift '5-speed' auto 1st to 5th gear ratios are 3.09, 2.2, 1.54, 1, & 0.71:1 Reverse 2.88. The TorqShift design in fact has six forward ratios, but only five are advertised, with the 'hidden' gear only used in extreme cold weather.

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, even though it was still considered an F-series truck. Instead of the aero look, it was more boldly angular with a raised hood and lowered fenders, somewhat like fender / hood medium truck style pioneered by the 1994 Dodge Ram pickup. An industry first, 2 big massive complete ring-style front tow hooks. 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 tall 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 (vehicle) for four Motorcycle
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 4-6 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-250 and related F-4000 were built in Brazil from 2000 to 2006. Brazilian trucks were widely exported to Australia(F-250), South Africa and Argentina (where they were sold as the F-100).


Second generation (2005-2007)

Because Ford Motor Company discovered that over 80% of the Super Duties were used for Towing heavy Trailer on a regular day-to-day basis [2], Ford restyled the line for 2005. Exterior styling was given a minor update with a new front end, however, this generation has major strength improvements.

Second Generation
2006 Ford F-350 Super Duty FX4
Also calledF-250
Model year2005-2007
AssemblyLouisville, Kentucky, USA
Escobedo, Mexico, Sao Bernardo do Campo, Brazil
Internal combustion engine5.4 L Modular V8
6.8 L Modular V10 engine
6.0 L Power Stroke diesel V8
Transmission (mechanics)ZF S6-650 transmission 6-speed Manual Transmission
5-speed 5R110W Automatic transmission
Wheelbase137 in (std. cab)
141.8 in (ext. cab short bed)
158 in (ext. cab long bed)
156.2 in (crew cab short bed)
172.4 in (crew cab long bed)
Length226.4 in (std. cab)
231.2 in (ext. cab short bed)
247.4/247.2 in (ext. cab long bed)
245.8/245.6 in (crew cab short bed)
261.8 in (crew cab long bed)
Width79.9 in (2,029 mm) (SRW)
95.5 in (2,426 mm) (DRW)
Height79.1 in (2,009 mm)
79.5 in (2,019 mm)
79.4 in (2,017 mm)
80 in (2,032 mm)
79.9 in (2,029 mm)
76.5 in (1,943 mm)
77 in (1,956 mm)
76.8 in (1,951 mm)
77.5 in (1,969 mm)
77.3 in (1,963 mm)
80.8 in (2,052 mm)
79.6 in (2,022 mm)
81.4 in (2,068 mm)
81.2 in (2,062 mm)
81.8 in (2,078 mm)
81.7 in (2,075 mm)
80.1 in (2,035 mm)
80 in (2,032 mm)
76.7 in (1,948 mm)
77.1 in (1,958 mm)
77.8 in (1,976 mm)
77.6 in (1,971 mm)
77.4 in (1,966 mm)
Fuel capacity29 US gal (110 L; 24 imp gal) (short bed)
38 US gal (144 L; 32 imp gal) (long bed)
RelatedFord Excursion
Ford F-250 crew cab

Major changes over the previous generation of Super Duties includes increased payload (Gross vehicle weight rating) & towing (Gross combined weight rating) capacities, a new taller front grille, new interior, standard locking Tailgate, 10-17% thicker partially boxed frame, higher amp Alternator (auto), upgraded & larger 4-wheel Disc brake (13.66-in front & 13.39 in (340 mm) rear rotors) with huge twin caliper pistons, upgraded engines, upgraded automatic transmission option, an all 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), an all new optional built-into-dash 4 AUX upfitter switches (for adding off road lights, winches, snow plows, etc.), and an optional drivers side glove compartment.

Ford F-350 Super Duty V10 crew cab

The front suspension on 4x4's use a solid front (monobeam) Dana Corporation Super 60 axle, but switched from leaf springs to coils and added a Sway bar. On 4x4 models there still is a choice of a BorgWarner manual gear-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 & (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 differential 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.

Ford F-550 Super Duty tow truck

The front suspension on 4x2 models is independent twin I-beam with coil springs.

The rear suspension on all models uses a 10.5-inch (270 mm) Visteon 35-spline axle with choices of conventional or limited-slip differentials in 3.73, 4.10, and 4.30:1 ratios. All models have heavy duty 3" wide Leaf spring and staggered Shock absorbers. A standard Sway bar on DRW (dual rear wheel) models. An optional slide-in camper certification package with heavier springs and an optional stabilizer bar package are available on SRW (single rear wheel) models.

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

The 6.0 L 32 valve pushrod actuated Power Stroke single-turbo diesel was also modified, boosting torque to 570 ft·lbf (770 N·m), but power remained the same as previous version with 325 horsepower (242 kW). Due to very high warranty exposure and over 500 vehicle full buy backs (due to the Lemon Law), late 2006 was the last of the 6.0 L diesels. The major problem with the Navistar diesel engines are due to damage resulting from defective fuel injectors. There were also minor problems resulting from the unreliable factory variable-vane turbocharger, EGR valve carbon deposit clogging/sticking, defective Exhaust Pressure (EP) sensor/connector, extensive PCM recalibrations, fuel injector harness chafing/crushing, general engine stalling/bucking, and inability to conform to the new Federal diesel emissions standards of January 1, 2007.

Ford's "Fail-Safe Cooling System" is unique. This system is designed to protect the engine due to loss of coolant (since these engines can not overheat for being 'overworked'). 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.

2005-2007 Ford F-350 Super Duty crew cab

Only 2 transmissions are available. 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. This Torqshift 5-speed transmission also became available on all versions of the trucks marketed. 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.

The TorqShift 5-speed auto 1st to 5th gear ratios are 3.11, 2.22, 1.55, 1.00, & 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. The 6-speed manual 1st to 6th gear ratios are 5.79, 3.30, 2.10, 1.30, 1.00, & 0.72:1. Trucks with the optional TorqShift 5-speed automatic are rated at exactly 1,000 lb (450 kg) higher towing capacity then trucks with the standard 6-speed manual transmission.

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 (it automatically locks the Torque converter providing power to the PTO gear when the operator turns on the PTO switch).

On 8' long bed models the fuel tank capacity is 38 gallons and the 6.75' short bed models are 29 gallons. Depending on models the optional trailer Tow hitch receiver comes with a 2" or 2.5" Class V receiver and 4- &/or 7-pin wiring harness in either 12,500 or 15,000 lb (6,800 kg). All Super Duties come with a Towing Package standard that includes an external oil and transmission coolers installed regardless if the factory hitch receiver was ordered or not. Depending on model and options, the empty title Curb weight is 6,000-8,000 lb.

2005-07 Ford F-350 Super Duty extended cab

Approximate Cargo capacities are 3,000 lb (1,400 kg) for the F-250 Super Duty, 4,000 lb (1,800 kg) for the F-350 Super Duty with Single Rear Wheels (SRW), and 5,800 lb (2,600 kg) for the F-350 Super Duty with Dual Rear Wheels (DRW). This generation of Super Duties has exactly double the payload capacity as compared to the older traditional (non-Super Duty) F-250 & F-350 trucks. By direct American comparison to the F-250 SD the Chevrolet Silverado is rated at 2,600 lb (1,200 kg) max and the Dodge Ram 2500 Heavy Duty is rated at only 2,100 lb (950 kg) max payload capacity.

Approximate Towing capacity for the F-350 Super Duty is 19,200 lb (8,700 kg) max. By direct American comparison Dodge Ram 3500 Heavy Duty is rated at 16,400 lb (7,400 kg) max and Chevrolet Silverado/GMC Sierra 3500HD is at 16,500 lb (7,500 kg) max.

Third generation (2008-present)

Third Generation
2008 Ford F-250 FX-4 crew cab
Also calledF-250
Model year2007-present
AssemblyLouisville, Kentucky, USA
Escobedo, Mexico
Internal combustion engine5.4 L Modular V8
6.8 L Modular V10 engine
6.4 L Power Stroke diesel V8
Transmission (mechanics)ZF S6-650 transmission 6-speed Manual transmission
5-speed 5R110W Automatic transmission
Wheelbase137 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)
Length227 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)
Width79.9 in (2,029 mm)
95.5 in (2,426 mm)
Height80.2 in (2,037 mm)
79.4 in (2,017 mm)
79.6 in (2,022 mm)
81 in (2,057 mm)
80.9 in (2,055 mm)
80.1 in (2,035 mm)
80.6 in (2,047 mm)
80.4 in (2,042 mm)
81 in (2,057 mm)
76 in (1,930 mm)
76.1 in (1,933 mm)
76.5 in (1,943 mm)
76.3 in (1,938 mm)
77 in (1,956 mm)
76.8 in (1,951 mm)
77.1 in (1,958 mm)
F-450: 79.8 in (2,027 mm)
76.4 in (1,941 mm)
76.2 in (1,935 mm)
77.2 in (1,961 mm)
76.7 in (1,948 mm)
79.4 in (2,017 mm)
79.9 in (2,029 mm)
2008 Ford F-350 SuperDuty regular cab

The Super Duty was going to be completely redesigned for 2007, but in May 2006 it was announced that quality issues have pushed it back to a 2008 model.[3] 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.[4] The new engine is said to produce 350 hp (260 kW) and 650 ft·lbf (880 N·m) of torque.[5]

After investing $95 million in the Kentucky plant on various upgrades and modernizations, Ford began production of the 2008 Super Duty trucks on December 18, 2006. However, the truck didn't go on the market until January 2007. The vehicle had its first official showing at the Texas State Fair in 2006.

This 3rd 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 & F-350 Super Duty basically has the same payload and towing specs as the last generation.

The model lineup for the F-250 & F-350 Super Duty is the XL (starting at $22,380), XLT (starting at $26,065), Lariat (starting at $31,785), FX4 (starting at $33,625), and the King Ranch (starting at $37,970).

The new FX4 model, which was once just an optional Off Road 4x4 package that could be added to any model in the lineup, is now replaced by the 4x4 Off Road Package. The all new FX4 is now considered a model of its own. It still has the same specs as the previous generation but with more of a sporty trim package included.

The model lineup for the F-450 Super Duty is the XL (starting at $39,205), XLT (starting at $44,980), and the Lariat (starting at $47,660).

The same 2 gas engines are carried over and rated exactly the same from the 2nd generation. The 3-valve 5.4 L (5408 cc, 330 cu in) V8 SOHC is standard. The 3-valve 6.8 L (6802 cc, 415 cu in) V10 SOHC is still a $600 option over the 5.4L V8.[4]

2008 Ford F-550 Super Duty

The diesel option is the new 4-valve Navistar 6.4 L (6400 cc, 390.5 cu in) V8 engine OHV Power Stroke twin-turbo diesel (PSD) engine (350 hp & 650TQ) with cast iron block & heads is a $6,895 option over the 5.4 L (5408 cc, 330 cu in) V8. The diesel engine utilizes Ford’s Clean Diesel Technology, which includes a high-pressure, common-rail fuel system, Piezo-electric fuel injectors and an advanced Diesel Particulate Filter (DPF) system. Ford claims that the new diesel systems reduce particulate output by more than 90% and allow the engine to post emissions numbers comparable with gasoline engines. Safety Product recall 07S49 was released on March 23, 2007 that addresses the potential for flames to come from the tailpipe of the International equipped 6.4 L diesel trucks. This problem arises from the tightening new diesel engine Federal Emissions standards starting January 1, 2007, requiring the use of an exhaust after-treatment system. A PCM recalibration has been released to eliminate the possibility of excessive exhaust temperatures combined with certain rare conditions resulting what is becoming known as a "Thermal Event".

Located near the same dash area as the last generation (but slightly to the right & 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.

For all 4x4 models, the transfer case 4x4 LOW range has a gear reduction of 2.42:1.

Another notable feature is an optional concealed slide-out step and swing-up hand grab bar in the rear tailgate to allow easier 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.

2008 Ford F-450 crew cab
Some unique points to highlight of the all new F-450 with a regular production pickup bed, which was only offered as a Chassis cab before. It has 2 available axle ratios of 4.30 & 4.88:1. The F-450 Super Duty with the optional 'High Capacity Trailer Tow Package' increases the GCWR (Gross combined weight rating) from 26,000 to 33,000 lb (15,000 kg). Maximum payload is 6,120 lb (2,780 kg). Maximum towing is 24,500 lb (11,100 kg). It comes standard with Crew Cab, 8-foot (2.4 m) long bed, DRW (Dual Rear Wheels), Limited Slip rear axle, 10-lug 19.5-inch (500 mm) wheels, Trailer Tow package, and the TowCommand TBC (Trailer Brake Controller). The only engine offered in the F-450 Super Duty will be the all new 6.4 L V8 Power Stroke twin-turbo diesel. The F-450 will be equipped with a standard 6-speed manual or optional 5-speed TorqShift Automatic transmission.

See also

Plasan Sand Cat


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