2008 Ford F-Series Super Duty

MORE CAPABILITY, MORE FEATURES AND MORE REFINEMENT FOR AMERICA’S LEADING WORKHORSE

• New F-450 pickup joins lineup, offering industry leading towing capacity in excess of 24,000 pounds and maximum payload of more than 6000 pounds
• New 6.4-liter Power Stroke ® Diesel delivers quiet, clean power
• All-new interior redefines tough luxury
• Industry-first, integrated Tailgate Step and stowable bed extender offer customer-driven solutions for cargo-hauling flexibility
• Industry-exclusive PowerScope power-fold, power-telescoping trailer-tow side mirrors enhance towing convenience
• Refined chassis and suspension improve ride and handling
• Exterior design changes maintain bold, American look, improve capability
• TowCommand™ System features integrated trailer brake controller
• TorqShift™ transmission improves towing performance
• Launch of full 2008 Super Duty lineup scheduled for early 2007

Ford F-Series Super Duty, the industry’s leading heavy-duty work truck and a mainstay of businesses throughout America, has been overhauled for the 2008 model year. Ford’s Super Duty pickup has been the leader in the over 8,500-pound truck segment since launch, offering best-in-class payload, gross vehicle weight ratings (GVWR) and trailer tow ratings. The new Super Duty, which will go on sale in early 2007, will help ensure that Ford Motor Company maintains its nearly 30 years of leadership in the pickup truck business.

Offered in three cab styles – Regular Cab, SuperCab and Crew Cab – and with two bed lengths, the new Super Duty will feature a bold look inside and out, an all-new, more powerful, state-of-the-art Power Stroke ® Diesel and a host of unique, innovative features not found on any other truck. And the line of Ford Super Duty trucks has been expanded for 2008, with an even more capable workhorse: the new F-450 pickup.

“The F-450 pickup doesn’t just raise the bar for heavy duty pickups, it tosses it out. Game over,” said Mark Fields, President of the Americas. “Every aspect of the new line of Super Duty trucks, including capability enhancements, design changes and feature innovations is uniquely designed after spending a great deal of time talking with – and listening to – our customers.”

Ford’s Super Duty set the standard in the over 8,500-pound truck segment when it was launched in 1998 as a 1999 model. Unlike competitors who simply modify their existing light-duty trucks, Super Duty utilizes its own unique architecture, designed and developed specifically to meet the needs and demands of the over 8,500-pound truck customer. This unique approach, with two dedicated architectures, is just one reason why the Ford F-Series has been America’s best-selling truck for 29 years and why Super Duty has dominated its segment, outperforming and outselling the competition every year since launch.

“We’ve been able to attract customers and pull big share numbers with Super Duty because we made the decision to set Super Duty apart from the rest of the segment,” said Cisco Codina, group vice president, North American Marketing, Sales and Service. “We’ve built our leadership reputation over time. Just being able to say that we’ve been America’s best-selling truck for 29 years says that we’ve been here, understanding and consistently meeting the needs of the true truck customer.”

For true truck customers, Super Duty is their life-blood, serving the multifaceted aspects of their lives. Whether towing a backhoe to the construction site or towing a boat to the lake, they demand a truck that is capable and dependable. Super Duty consistently meets those needs.

“The Super Duty customer isn’t the guy who buys a pickup because it’s cool to have a pickup. These guys are working with this truck,” said Ben Poore, Ford Truck marketing manager. “They’re hauling and towing, often earning their living with their trucks, and their truck has to be as reliable and dependable as they are.”

 

All-new F-450 pickup adds capability for customers who demand the most

Today’s Super Duty customers are consistently searching for more capability. Ford research has shown that more than 90 percent of Super Duty owners tow, and their towing needs are growing. To meet that need, Ford is introducing the new F-450 pickup model. It combines the right axle, right powertrain, and right suspension to manage the loads of pulling a heavier trailer while maintaining a refined, comfortable ride.

For example, the F-450 pickup rides on its own unique chassis. It incorporates a new rear leaf-spring suspension while u sing the radius arm front suspension from the F-450 chassis cab. This set-up provides for the tightest turning radius in its class, greatly improving maneuverability when towing.

“The increased towing and cargo hauling capability, the engine enhancements and all the refinements make the F-450 absolutely the most capable pickup truck we’ve ever built—period. And that is exactly what our customers are asking for,” said Pete Reyes, Super Duty chief engineer.

According to a study by the Recreational Vehicle Industry Association (RVIA), towable RV shipments have grown steadily over the past five years, topping out at 323,000 units shipped in 2005, a 15.4 percent increase over 2004. In the same time frame, conventional motor coaches experienced a decline in sales, with shipments of the Type A variety down 18.1 percent in 2005.

The RVIA says that higher fuel prices and a desire for more flexibility are driving customers out of conventional motor coaches and into towable travel trailers and fifth wheels. And as these customers move to towable trailers, they will still expect to have the same level of luxury features – such as tile floors, granite countertops and big-screen TVs – as they had in their motor coaches. For example, almost 90 percent of fifth-wheel RVs shipped in 2005 had at least one fold-out room, according to RVIA data.

The 2007 F-350 Super Duty already offered best-in-class maximum payload of 5,800 pounds and maximum towing capacity of 19,200 pounds. The new 2008 F-450 pickup widens the capability gap, offering a maximum payload of more than 6,000 pounds and towing capacity of more than 24,000 pounds – a 5,000-pound increase over the class-leading F-350. All of this added capability comes with the same increased level of refinement found in the new F-250 and F-350.

“Customers tell us they want to tow and the F-450 delivers,” said Reyes. “The trailer builders will be writing us thank-you letters because they can sell trailers with granite counter tops and fireplaces. And adding another horse to the trailer is no problem for the F-450 pickup.”

 

All-new 6.4-liter Power Stroke ® Diesel is cleaner, quieter and more powerful

A more powerful 6.4-liter Power Stroke ® Diesel joins a powertrain lineup that already includes the segment’s most powerful gasoline engine, the 362-horsepower 6.8-liter V-10 Triton.

Annual U.S. diesel truck registrations have increased to more than 500,000 a year from about 400,000 in 2001. Ford has long been the industry leader, selling 1.3 million diesel-powered F-Series pickups in the United States since 2001 alone. Ford sells more diesel-powered pickup trucks annually than Chevrolet and Dodge combined. Nearly three-quarters of all Ford Super Duty trucks sold are diesel-powered.

The new engine benefits from an innovative development process designed to more accurately reflect how Super Duty customers use their vehicles every day. The team began by collecting real-world data from working Super Duty commercial customers, tracking their daily duty cycles. That data was used to develop durability tests that more closely represented real-world use. To better assure durability, the tests were conducted using the most extreme and abusive conditions and run to five-times the life cycle that the hardest-working truck would ever experience.

“By the time we launch this vehicle,” said Dan Davidson, Powertrain supervisor, “the engine will have seen more than 10 million equivalent miles of testing both on the dyno and in test vehicles.”

The 6.4-liter Power Stroke ® Diesel delivers 350 horsepower at 3,000 rpm and 650 lb.-ft. of torque starting at 2,000 rpm and utilizes Ford Clean Diesel Technology, which includes, among other features, a high-pressure, common rail fuel system, Piezo-electric fuel injectors and an advanced diesel particulate filter system to deliver strong performance while reducing particulate output by more than 90 percent and posting emissions numbers on par with gasoline engines.

High-tech, series sequential turbochargers provide improved response and better low-end performance. The unique system uses a small, electronically controlled, smart remote variable geometry turbocharger that comes on at low rpm to provide extra boost at take-off. As rpms increase, the larger fixed turbo joins the smaller turbo to boost power through the middle of the torque curve. As optimum speed is reached, the larger turbo takes over. Tests have shown zero-to-60 times of more than a second faster than the outgoing 6.0-liter.

Transmission choices include a six-speed manual with overdrive or a TorqShift™ five-speed automatic. The powertrains use a new unique mounting system that better isolates the powertrain and reduces vibration. Both two- and four-wheel-drive models will be available on the 2008 Super Duty.

 

New interior provides quiet comfort and improved ergonomics

The all-new interior builds on the successful tough luxury design established by the Ford F-150 and advanced for Super Duty, increasing capability, quietness and refinement to levels never before available in Super Duty’s segment.

“We know people are spending more time in their trucks, and this is especially true for the Super Duty customer,” said Poore. “The truck is their office. It’s where they do their business. It’s important to not only meet their capability needs but also the comfort and styling needs as well.”

The sharp, modern design features all-new materials and includes luxury touches like contrast stitching on the seats and rich, Chaparral leather on the King Ranch. Like the exterior, Super Duty’s interior was designed to be functional and capable while still delivering a high level of quality and craftsmanship with a luxurious look.

Designers combined rich surfaces with elements borrowed from high-end power tools and butcher block-style wood accents to define the tough-luxury interior.

“Think of it like a modern kitchen, in a way,” said Pat Schiavone, Super Duty chief designer. “A kitchen can be very stylish and look very expensive, but it also must be very functional. It was that kind of thinking that drove tough luxury.”

The prominent center stack houses most of the vehicle’s switches, integrating all functions into one easy-to-reach central area. The auxiliary switches and Trailer Brake Control system are now fully integrated into the center stack for a cleaner, user-friendly appearance.

The rings surrounding the gauges and air vents are notched, more angular and defined. The gauges are also better organized and easier to read. All-new door trim features dual map pockets that are better integrated into the interior. A large center console is designed to hold file folders and keep laptop computers tucked out of sight.

Super Duty utilizes several innovative technologies to provide an ultra-quiet cabin. Quiet Steel ®, a unique composite laminated steel sheet, makes up the vehicle’s dash panel and works with extra sound padding in the dash and floor, a rear bulkhead panel and thicker side glass to help keep unwanted noise out of the cabin.

A totally redesigned climate control system has more balanced airflow and refined, quieter operation that improves cabin comfort. The system uses a more reliable, more durable, higher capacity compressor, one of the many components that contribute to the better performance of the A/C system. Floor ducts for the heater now run under the seat, out of site of the rear-seat passengers.

Dual-zone Electronic Automatic Temperature Control (EATC) has been added as a standard feature on the Lariat and King Ranch for 2008, allowing the driver and front passenger to set individual temperatures. Diesel customers can opt for the innovative Rapid Heat supplemental heating system – the first of its kind in North America – that augments the diesel truck’s heater to provide faster warm-up on cold mornings.

“Diesel truck owners will love this,” said Poore. “They’ve come to expect a certain level of performance from their trucks. This system will surprise them.”

All audio systems are now MP3 capable and feature a standard auxiliary audio input. The input allows an MP3 player to play through the vehicle’s stereo system. Super Duty customers can also now opt for a premium a udiophile system, featuring eight speakers with subwoofer and 6-disc CD changer.

A DVD-based navigation system with an in-dash screen is available on FX4 and Lariat SuperCabs and Crew Cabs. Rear seat passengers can enjoy the DVD Entertainment System – available on XLT, FX4 and Lariat Crew Cabs – with an eight-inch video screen, two wireless headphones and remote control.

 

Exterior design maintains bold, American look, improves capability

Super Duty designers have delivered a truck that makes a bold design statement by emphasizing Super Duty’s increased capability. The larger, more prominent grille, sharply sculpted fender flares and fender-mounted air vents are just a few of the new design cues that announce that Super Duty is all about working hard.

“The design of the 2008 Super Duty was driven by the improvements in the capability of the truck.” said Schiavone. “For example, we started by raising the nose and enlarging the grille to improve cooling, which in turn improves towing performance.”

Super Duty’s impressive, larger grille not only makes a bold statement, but also helps improve cooling, which in turn improves, among other things, trailer towing capability.

The grille sits on a horizontal cut line that defines the top of the bumper and also serves as a base for the stacked headlamps, delivering a clean, tight and more refined look. The step pad on the front bumper is specifically textured and designed for the customers who use the bumper while servicing the truck

Super Duty proudly announces itself with a large Ford Blue Oval badge sculpted into the grille and “SUPER DUTY” embossed into the grille’s leading edge – a tribute to Ford’s truck heritage – harking back to the embossed FORD letters on the tailgate of the original F-Series.

The raised grille emphasizes the sculpted sides of the powerdome hood and carries the theme to the air vents mounted on the fender just behind the crisply defined wheel arch. The vents dissipate engine compartment heat and designate the type of powertrain beneath the hood – red for diesel, black for gasoline.

The distinctive dropped beltline, a Ford truck design cue, improves visibility and carries the eye rearward to the revised tailgate, with the Lift-Assist System now standard across the model range, and the Ford oval mounted front-and-center, flanked by redesigned tail lamps. A deeper rear bumper helps to balance the design while providing easier access to the bed.

Five all-new wheel designs including standard 18-in. premium chromed steel wheels on Lariat and 20-in. premium polished forged aluminum wheels join a list of 10 wheel options across the line-up.

Along with XLT, Lariat and high-line King Ranch models, the 2008 Super Duty now offers an FX4 model available on 4×4 SuperCab and Crew Cab. The FX4 includes skid plates, Rancho branded dampers, a special body-color billet-style grille and many other features. The FX4 is available in five colors including a new Dark Blue Pearl Clearcoat Metallic (also new for King Ranch) over Shadow Grey Clearcoat Metallic. Forest Green Clearcoat Metallic replaces Forest Green Satin Clearcoat Metallic and a brighter, richer Pueblo Gold Clearcoat Metallic replaces Arizona Beige Clearcoat Metallic as the lower color on XLT, Lariat and King Ranch two-tone models.

 

Innovative ideas: industry-unique Tailgate Step and stowable bed extender

Ford’s unique relationship with the Super Duty customer has fostered the kind of innovation that creates products like the Tailgate Step and stowable bed extender. These new features are available only on Super Duty and designed specifically to meet the needs of Super Duty customers, making their jobs easier.

The optional Tailgate Step and the two-piece stowable bed extender provide customers with the convenience of using these systems when they need them, but at the same time not requiring the removal of the systems when they are not in use.

“When we see how people are working with their trucks, we react to that,” said Poore. “One example is the Tailgate Step. If you go to any job site and see how people get up into the back of the truck, hopping into the bed or climbing up on the tire, you say, ‘There has got to be a better way.’ That’s the genius behind the Tailgate Step, looking at the market and solving the need with an intuitive feature.”

The Tailgate Step is fully integrated into the tailgate and virtually invisible when not in use – the entire feature is housed in the tailgate with the lower step becoming the center of the top rail of the tailgate when not in use. To use the step, simply drop the tailgate into the down position, grab the bottom step, pull it straight out from the tailgate and drop it down into the step position – all in one easy motion. The 16.7 by 4.5-inch flip-down step pad makes it easy to step up into or down out of the bed to load or unload cargo.

The Tailgate Step is as tough as the Super Duty, made of high-strength steel construction, is MIG welded for added strength, and has been tested up to 1,000 pounds.

A unique grab handle folds up and out of the tailgate to provide extra support when using the Tailgate Step, supporting up to 300 pounds. When not in use, the grab handle fits snuggly into a channel molded into the tailgate inner-liner. For added safety, the tailgate liner has an added coating creating a non-slip walking surface.

“It’s just another example of the way we innovate differently,” said Poore. “I have seen guys who have made their own version of a step, but none as cleanly integrated into the truck.”

The stowable bed extender works like any other, extending storage space to the end of the bed, or it can set inside the tailgate leaving a small, enclosed section that keeps cargo from sliding forward near the cab. But the similarities end there. This innovative extender separates into two pieces that fold and snap securely to the sides of the bed, allowing full space and functionality of the bed when the extender is not needed.

Super Duty’s stowable bed extenderis made of strong, blow-molded polypropylene, is impact and corrosion resistant and can withstand up to 1,000 pounds of static pressure. The 21-inch tall cage folds out, clamps together in the center and is secured to the bed with a bolt-action latch. It easily folds out of the way when not needed and secures to the inside of the bed.

Industry-first PowerScope integrated power-fold, power-telescoping mirrors

Super Duty continues to lead the pack when it comes to towing and capability by offering such innovations as the industry’s first power-fold and power-telescoping side mirrors.

Industry-exclusive power-fold and power-telescoping side mirrors combine improved functionality with a design that has been toughened to match the Super Duty’s good looks. The large mirrors extend outward up to 2.75 inches and feature a power-adjustable main mirror with a manually adjusted spotter mirror that is more than double the size of the previous generation, greatly improving visibility. The mirrors telescope or fold at the touch of a switch mounted to the windowsill and are integrated into the vehicle’s seat-position and pedal-memory system. The mirrors also feature heated glass, clearance lamps and integrated turn signals.

 

Proven chassis and revised suspension deliver refined capability

Super Duty’s superior ride and handling and class-leading capability are the result of a rugged chassis and refined suspension designed specifically to meet the growing needs of today’s customers.

Every 2008 Super Duty frame now has a new front stub designed with safety in mind. By lowering the frame horns seven inches at the front, the new frame meets vehicle compatibility standards without the need for add-on components. The new design also improves cooling and provides a solid foundation for the hydroformed body structure. Every Super Duty frame is e-coated for improved corrosion resistance.

The newly designed leaf-spring rear suspension delivers superior ride and handling in all load situations. The eight-inch longer springs attach farther forward on the frame giving the vehicle more balance and better control. New damper tuning further improves Super Duty’s confident feel on the road.

The Super Duty is the first truck in the industry to use a high-strength steel front body structure. The patented structure, made up of two side rails that are welded to the bulkhead and frame, not only serves to create a very rigid foundation, the system’s modular construction eases assembly and delivers higher quality and better fit and finish.

The revised frame and front-end structure enables a Front Gross Axle Weight Rating (FGAWR) increase to 5,250 pounds on 4×2 F-250 and F-350 trucks. A 12.5K trailer hitch is now standard on F-250/350 SRW and some F-350 DRWs. A 15K hitch is standard on most F-350 DRWs and all F-450 pickup models receive a 16K hitch.

 

Exclusive features add to Super Duty’s towing prowess

Ford’s available TowCommand™ System still includes the industry’s first factory-installed and warranted electronic trailer brake controller, offering smoother operation and safety features. This includes a special trailer brake strategy for when the truck’s anti-lock braking system detects poor traction. No aftermarket trailer brake controller can provide this.

Ford’s TowCommand™ System also includes the TorqShift™ transmission with tow-haul mode and trailer tow mirrors. TorqShift™ with tow-haul mode changes shift points under acceleration, keeping the truck at a higher rpm and further up in the power range. Tow-haul also prevents the transmission from upshifting when the vehicle crests a hill, and it provides downhill braking that allows the transmission to downshift, letting engine-compression braking slow the vehicle and maintain a steady speed while going downhill.

 

CHASSIS

ALL-NEW 2008 SUPER DUTY CHASSIS PROVIDES INCREASED STRENGTH AND DURABILITY WITH IMPROVED RIDE AND HANDLING

• The 2008 Super Duty rides on a refined, stronger chassis.
• Every Super Duty frame is now e-coated for improved corrosion protection

All new rear leaf spring suspension design for the F250, F-350 and F-450 pickup improves ride and handling without compromising capability
Class-exclusive patented engine-torque traction control system is more precise than competitors brake-based systems
Patented hydroformed steel front structure creates a strong foundation for engine compartment components. Modular construction eases assembly and delivers a more dimensionally accurate truck
The 2008 Super Duty’s tough truck capability starts with a solid foundation. From the F-250 pickup, F-350 pickup, F-450 pickup, right up to the F-450 and F-550 chassis cab, each chassis is custom-tailored to provide the utmost in strength, flexibility and durability.

Every Super Duty frame is E-coated for improved corrosion protection. The new, fully boxed front section has been optimized to meet the government’s standards for vehicle compatibility without the need for an added blocker beam. The unique front frame horn design lowers the frame by seven inches, improving vehicle cooling and providing a solid footing for the hydroformed body structure.

Robust, 6.7 mm steel outer rails (8.1 mm on the chassis cabs) utilize cross members that have been modified to help with powertrain noise isolation. Super Duty’s cross members are riveted and welded for added strength.

“Some trucks have welded cross members and some have riveted cross members,” said Bruce Arnold, Chassis Systems Integrator. “Only Super Duty has both.”

Reinforcements have been added to several areas for increased cargo and towing capacity. Massive 27mm enclosed tow hooks, “the strongest tow hooks in the industry,” are designed to support one-and-a-half times the trucks gross vehicle weight – up to 33,000 pounds.

 

Proven front suspensions are tweaked for added capability

Super Duty combines a proven front suspension with an all-new rear leaf-spring suspension to deliver a more refined and confident ride without compromising on capability.

All F-250 and 350 4×4 pickups utilize a moonbeam, coil-spring front suspension geometry that provides better steering feel and response and enables class-leading braking. The 4×4 suspension enables a dramatically reduced turning circle and the front radius arms act as “anti-wind-up” bars improving traction and reducing wheel hop under hard acceleration.

The proven twin I-beam front suspension remains the choice for all 4×2 F-250 and F-350 models. Front bushings were stiffened and the front stabilizer bars were redesigned with new links for improved ride and handling. Front Gross Vehicle Weight Rating (FGAWR) has been increased from 4,800 to 5,250 pounds. A new steering damper reduces vibration for a confident feel.

“We actually have a new process in how the steering gear goes together,” said Dan Gompper, vehicle dynamics supervisor, “to help with isolation.”

The F-450 utilizes the more-capable, wide-frame monobeam front suspension from the F-450 chassis cab and features a large 35 mm front stabilizer bar, new for 2008. The large, square axle tubes not only look strong, but are also design to deliver improved towing performance and capability.

“These are some really tough, impressive looking axles,” said Gompper. “They add to the performance and the look of the F-450 pickup.”

 

New rear leaf spring suspension results in confident ride and handling under all load conditions

All Super Duty pickups including the F-450 pickup, feature a new rear leaf-spring suspension design that provides the same high levels of capability with increased levels of refinement. The eight-inch longer springs attach farther forward on the frame and contribute to the confident feel of the vehicle.

The new design reduces power hop and brake hop and enables more “wind-up” stiffness with no degradation in ride. The suspension uses stiffer bushings all the way around with a redesigned rear linkage. As an added benefit, the rear suspension was specifically designed to keep the rear end lower to optimize the towing of taller gooseneck and fifth-wheel trailers.

“The longer leaf springs, stiffer bushings and position of the front attachment, give the vehicle more balance, more control,” said Gompper. “Super Duty’s road manners make it a pleasure to drive when towing for long distances.”

The redesigned leaf springs and stiffer bushings also help to improve front and rear roll control during cornering, keeping the suspension underneath the truck relative to the frame.

“By controlling that initial reaction, you reduce the chance that the body will build momentum sideways relative to the axle,” said Gompper. “The axle has grip, the body is stuck firmly to the axle and they both carve smoothly around the turn.”

The staggered rear shocks, feature new tuning across the board, and bolt to new upper and lower shock mounts. An improved ratio provides for a smoother ride. The F-450 pickup has its own unique tuning designed specifically to compliment the truck’s increased towing capacity. Diesel trucks have a new boost curve on the diesel power steering gear to improve parking efforts.

Gompper’s team set high targets for gain linearity. As a vehicle is driven into a corner, the steering wheel will send feedback to the driver. Gain linearity is the measurement of how the steering communicates to the driver from the initial turn of the wheel until the vehicle exits the corner.

“Good gain linearity delivers a smooth transition, keeping the driver in complete control,” said Gompper. “With all the Super Duty pickups including the F-450, we’ve managed to combine light steering efforts and good response linearity. That contributes to the confidence you get, especially when towing a heavy trailer.”

Patented engine-torque traction control delivers precision handling

The 2008 Super Duty is the only vehicle in its class to utilize a sophisticated type of patented engine torque traction control on all diesel models. While most competitors use brakes to manage torque, Super Duty’s state-of-the-art diesel uses engine torque to manage wheel spin. Super Duty’s system computes wheel speed from the differential and reduces torque to match the best traction to the wheels for that terrain. The system works in 4×2 only and offers the option of shutting it off when it’s not needed

“Engine torque traction control is much more precise that brake-controlled traction control,” said Gompper, “because it drives you to the best friction point for tires to surface.”

 

Hydroformed front structure builds strength and accuracy

The Super Duty is the first truck in the industry to use a high-strength steel front body structure. The patented structure not only serves to create a very rigid and strong foundation, the systems modular construction eases assembly and delivers a more dimensionally accurate truck, increasing quality and providing a more precise fit and finish.

The front structure, made up of two side rails that are welded to the bulkhead and frame. The front-end module, housing the cooling system, bolts to the front of the rails to form a rigid, solid structure. The fenders bolt firmly to the modular structure that also houses the rest of the front end and under hood components, such as headlamp assemblies, battery, air box and fluid reservoirs for the windshield washers and cooling system.

All the framing is done at one station in the body shop. The rails are loaded with the dash panel and body side and securely welded to the dash panel and A-pillar for added strength, providing both a dimensionally accurate and exceptionally strong structure.

What’s most impressive is that the body engineering team had to create a new set of development procedures, as they had nothing in the industry to benchmark. Much of the initial development work was done in the computer using a computer-aided drafting (CAD) program, producing some very tough prototypes.

“We got a letter from the guys at the Arizona Proving Ground, commending us on the design of the truck,” said Dragan Stojkovik., body structures engineer “They were impressed, because they couldn’t break it.”

 

POWERTRAIN

REVOLUTIONARY NEW DIESEL AND SEGEMNTS MOST POWERFUL GASOLINE ENGINE PROVIDE CLASS-LEADING CAPABILITY

• New 6.4-liter Powerstroke® diesel with Ford Clean Diesel Technology® provides and increase in performance with a sharp decrease in particulates and emissions
• Sequential turbochargers improve off-the-line performance with smooth acceleration through the power band
• High-pressure, common rail fuel system includes the precision of Piezo-electric injectors deliver quiet operation without compromising performance
• Advanced engine electronics control module with advanced softwareenables state-of-the-art engine technologies
• The 6.8-liter, three-valve Triton™ V-10 produces 362 horsepower and 457 pound-feet of torque – both class-leading figures.
• Thirty-three percent larger radiator and larger water pump designed to handle the utmost of extremes, provide more power
• Ford is leading the diesel revolution with the 2008 Super Duty, offering the segments first clean diesel engine. The new 6.4-liter Powerstroke® turbo-diesel joins an already strong line-up that includes the segments most powerful gasoline engine, the 6.8-liter Triton® V-10.

 

High-tech Powerstroke® turbo-diesel is more powerful, more capable

The new 6.4-liter diesel utilizes Ford Clean Diesel Technology™ to deliver the best PowerStroke® diesel ever. The new powerplant meets the most stringent emissions standards in the world, while still increasing power and torque in an engine that is smooth and quiet.

“We had to put in this level of technology to meet emissions,” said Dan Davidson, Powertrain Supervisor. “We went up in displacement to improve torque and horsepower as well. Effectively we said, ‘if we’re going to do a new engine to meet emissions, then let’s improve performance as well.’ We didn’t compromise on anything.”

The 6.4-liter PowerStroke® clean-diesel makes an impressive 350 horsepower at 3,000 rpm and 650 foot-pounds of torque starting at 2,000 rpm while reducing particulate output by up to 97 percent and posting emissions numbers on par with gasoline engines.

A tough, cast iron block and heads provide a strong, durable foundation for making power and torque. A new cylinder head design and piston bowl design optimize the high-cylinder pressures delivered by the high-pressure fuel system. The higher pressures provide more efficient combustion equating to increased power and cleaner emissions.

The pistons mount to the forged-steel crankshaft with larger, stronger rods that feature an increased rob bearing diameter. The pistons are galley-cooled providing optimized operation and increased durability.

 

Two turbos are better than one

The high-tech, series sequential turbochargers provide improved response throughout the entire power band with better low-end performance. Tests have shown zero-to-60 times of more than a second faster than the outgoing 6.0-liter.

The two turbochargers work in tandem. The small, electronic-controlled, smart remote variable geometry turbocharger comes on at low rpm to provide extra boost at take-off. As rpms increase, the larger fixed turbo joins the smaller turbo to boost power through the middle of the torque curve. As optimum speed is reached, the larger turbo takes over.

The system can make up to 42 pounds of boost and is bolted to the engine with mounting brackets designed to reduce NVH. The turbos themselves have been optimized against oil coking.

 

High-pressure fuel system makes quiet power

Clean diesel is fed to the engine via a state-of-the-art, high-pressure common rail fuel injection system. Fuel, pressurized to 26,000 PSI (1,800 bar) is injected into the cylinders through class-exclusive Piezo-electric injectors. The latest in injector technology can deliver up to five injections per combustion cycle to better control emissions, provide instant response for optimized acceleration, and improve cold start down to –20 degrees Fahrenheit.

Piezo technology is also the enabler behind the PowerStroke®’s quiet, gasoline-engine noise levels, further enhanced by mounting the injectors under the valve covers.

Innovations reduce emissions with improved fuel economy and durability

Dual 440 mm EGR coolers feature an air oxidation catalyst that literally scrubs the exhaust gasses from the air to protect coolers against fouling and the EGR valve against deposits.

The EGR valve itself is impressive. The self-cleaning valve features a high torque, high-flow, dual poppet DC electric motor that increases actuation force to 400N. The engine management system monitors the valve checking for the slight buildup that can impair the valves ability to seat securely. The module reads these “soft closings” and takes the necessary steps to clean the seat.

The Powerstroke®’s engine control module (ECM) has been improved for 2008. Fuel controls and engine controls are now integrated into the same, rugged cast aluminum housing, enabling proper operation of the state-of-the-art engine technologies. The ECM durability tests have been increased by two times to insure robustness and long life.

The highly efficient, exhaust system combines engine and emissions-control technologies such as the diesel particulate filter (DPF) and oxidation catalyst into a close-knit system, removing nearly 97 percent of the diesel particluate. The system has been optimized for performance. For example, extensive use of Computer Aided Engineering (CAE) tools optimized flow to reduce losses.

“We took a real hard focus at the minute details of the design and the angles of the transitions as you go from part to part,” said Davidson.

 

An all-new engine from an all-new development process

The New 6.4L diesel is more than just a clean sheet of paper engine. It benefits from an innovative clean-sheet-of-paper development process that optimized durability, performance, fuel economy and emissions.

“The Super Duty program set the precedents for this new process,” said Davidson, “and the results have been nothing short of amazing. Our initial durability test vehicles exhibited near-zero issues in reference to powertrain.”

The focus of the program was to design a development process that more accurately reflected how Super Duty customers used their vehicles everyday. The team began by collecting real-world data from working Super Duty commercial customers, tracking their daily duty cycles.

The data was used to develop durability tests that were more representative of these real-world duty cycles. For example, this was the first time that dynamometer tests were run with the transmission bolted to the engine during the durability run, allowing engineers to see how the up-shifts and downshifts affected the powertrain during the duty cycle.

The tests were conducted using the most extreme and abusive conditions and run to five-times the life cycle that the hardest-working truck would ever experience, further assuring durability,

“By the time we launch this vehicle,” said Davidson, “the engine will have seen more than 10 million equivalent miles of testing both on the dyno and in test vehicles.”

The extended testing hours allowed the team to scrutinize every component and system under theses customer-driven conditions. As a result, more than 500 design improvements were made to the diesel powertrain to improve performance and durability.

Powertrain options include the segment’s most powerful gasoline engine

The all-new 6.4-liter turbo diesel joins a proven gasoline powetrain line-up that includes the 6.8-liter, three-valve Triton™ V-10 that makes 362 horsepower and 457 pound-feet of torque – both class-leading figures.

Customers can also choose Ford’s modular 5.4-liter, three-valve Triton™ V-8 that delivers 300 horsepower and 365 pound-feet of torque. More than 80 percent of peak torque – nearly 300 pound-feet – is available starting as low as 1,000 rpm.

Both engines benefit from electronic throttle control, which provides economy and performance benefits. For commercial users who need elevated engine speed to run aftermarket power takeoff (PTO) systems, the “stationary elevated idle control” feature is available on all models.

The gasoline engines feature all-new exhaust systems and newly designed air boxes that mount solidly to the new modular front structure. Transmission choices include a six-speed manual with overdrive or a TorqShift™, Five-speed automatic. The transmissions utilize a new, unique mounting system that better isolates the powertrain and reduces vibration.

Transmissions feature all-new gear sets and a three-plate, two-stage torque converter to reduce turbine noise when the converter is locked. The F-450 uses upgraded synchronizers to enable electronic shift on the fly.

Keeping it cool increases power and durability

The Super Duty cooling system has been designed to handle the utmost of extremes. Engineers based the system tests on the F-550 chassis cab’s pulling gate of 33,000-pounds, combined weight.

“Our cooling targets are more stringent,” said Rick Murty, cooling engineer. “We shoot for lower cooling temperatures than the competition. We run the competition through our tests and their temperatures are about 30 degrees higher than ours. That 30 degrees of cooling turns into more towing power and more torque.”

Super Duty’s radiator has grown by 33 percent and a larger water pump nearly doubles flow rate from 75 to 140 gals per minute.

A larger fuel filter better separates water from the fuel, an important asset with the onset of biodiesel. Ford recommends B5 (5 percent biodiesel) for Super Duty’s 6.4-liter PowerStroke turbo Diesel.

 

EXTERIOR/INTERIOR

BOLDER, TOUGHER DESIGN AND STATE-OF-THE-ART INTERIOR SET NEW STANDARDS FOR THE MEDIUM-DUTY TRUCK SEGMENT

• Bold exterior design visually embodies Super Duty’s increased capability
• Larger, bolder grille sets the tone for toughness, proudly wears embossed SUPER DUTY name
• All-new 20-inch forged, polished aluminum wheels and tires available on all models with the exception of King Ranch which gets its own unique Premium Painted Forged Aluminum wheel
• Rugged, modular interior design adds capability and improves ergonomics
• Auxiliary audio input jack standard on XLT, FX4 and Lariat
• Navigation Radio with in-dash screen available on FX4 and Lariat
• Rear Seat DVD Entertainment System (91D), available on XLT, FX4 and Lariat Crew Cabs, including a roof-mounted DVD system and 8-in. video screen, two wireless headphones and remote control

The 2008 Super Duty’s bold, in-your-face design furthers the “Built Ford Tough” legacy, emphasizing Super Duty’s increased capability while providing a high level of craftsmanship. Inside and out, Super Duty’s design sets new standards, delivering a truck that makes a visual statement that it’s ready to work hard, yet conveys a refinement not expected of a vehicle in this class.

“We wanted to do the toughest looking truck ever, but we wanted to make sure it looked refined, in terms of the fit and finish,” said Ed Golden, Super Duty chief designer. “We attached the grille to the hood, which accentuated the refined look and drove all of the margins to the area above the bumper.”

The grille reinforces the functional/capable aspect of Super Duty’s design, providing increased cooling for improved towing power. Sitting four-inches higher than the previous model, the grille defines the powerdome hood and proudly wears the Super Duty name embossed across the leading edge, a tribute to Ford’s truck heritage, harking back to the embossed FORD letters on the nose of the original F-Series. Two prominent nostrils, a Ford truck design mainstay, flank the grille on either side.

Everything about Super Duty has been made stronger and more capable. A larger Ford oval badge is more precisely fixed to the grille, sitting in a strong frame. New, larger stacked headlamps sit four inches lower than the previous model providing improved functionality and compatibility with other vehicles.

A horizontal cut line running along the top of the semi-truck inspired bumper, serves to line up the bottom of the grille and headlamps, delivering a clean, tight and more refined presentation. The functional/capable design theme is evident in the integrated step pad on the front bumper, designed to support those who like to work on their trucks.

Super Duty retains its distinctive dropped beltline, a Ford truck design cue that improves visibility. Crisply defined fender flares wear air vents inspired by the F-350 TONKA concept truck. The vents serve to identify the engine that lies beneath the powerdome hood. Red signifies diesel while black is used for the Triton™ gasoline engines. Industry-first, power telescoping, power fold mirrors were expertly massaged to provide the best balance between functionality and design.

The pickup box wears a new tailgate with the Ford Blue oval moved to the center and the SUPER DUTY name embossed on the lower edge. The Lift-Assist System is now included on all tailgates. New taillamps grace the corners and the larger, wider rear bumper, housing the four-pin/seven pin trailer connector with shared hinge, was toughened up to improve capability and to help balance the overall design.

Customers wishing to add a sense of personal style to their trucks can choose from 10 new wheels for 2008. The F-250 and F-350 base 17-in. wheel comes in forged polished aluminum on FX4 and Lariat DRW and is available on the XLT DRW. Six new 18-in. wheels include exclusive premium chrome steel wheels on FX4 painted aluminum wheels on King Ranch. A 20-in. polished forged aluminum wheel is available on XLT, Sport, FX4 and Lariat and the King Ranch gets its own 20-inch Premium Painted Forged Aluminum. The F-450 pickup rides on the same 19.5-in. tires found on the chassis cabs for improved capability.

Super Duty has several established colors, such as red and white. Many of these colors launched with the first Super Duty and have become corporate colors for many fleet buyers. All of Super Duty’s exterior colors have been modified for 2008, delivering a brighter, cleaner appearance.

Three new colors, Dark Blue Pearl Clearcoat Metallic, Forest Green Clearcoat Metallic and Pueblo Gold Clearcoat Metallic, join the lineup for 2008. XLT, Lariat and FX4 offer six unique two-tone paint schemes including Dark Blue Pearl Clearcoat Metallic and Forest Green Clearcoat Metallic over Pueblo Gold Clearcoat Metallic and Pueblo Gold Clearcoat Metallic over Black Clearcoat (Lariat only). FX4 comes in Dark Blue Pearl Clearcoat Metallic, Red Clearcoat, Black Clearcoat, Oxford White Clearcoat and Silv er Clearcoat over Dar Shadow Grey Clearcoat Metallic.

King Ranch offers a choice of Dark Blue Pearl Clearcoat Metallic and Black Clearcoat over Pueblo Gold Clearcoat Metallic.

 

State-of-the-art interior provides improved comfort and ergonomics

The 2008 Super Duty once again sets new standards for interior comfort and capability. Designers combined quality craftsmanship and materials with a clean, modern execution that emphasizes Super Duty’s refinement and capability.

“The F-150 set the initial standard and the 2007 Expedition raised it again in its segment,” said Golden. “The 2008 Super Duty continues to raise the standard, but does it in a way that appeals to the customer who’s looking for tough and robust without compromising luxury.”

Designers focused on creating an interior that is an extension of the customer’s toolbox. The rugged, modular design is inspired by the high-end tools that customers use everyday and also enables the distinctive differentiation between trim levels.

The prominent center stack carries the “powerdome” theme inside the vehicle and houses most of the switches, integrating all functions into one, easy to access, central area. The auxiliary switches and Trailer Brake Controler switches are now better integrated into the center stack for easy access and a cleaner appearance. The center stack on XLT, FX4 and Lariat wears a foundry-metallic paint that carries over to the instrument panel straps. The King Ranch center stack is trimmed in a rich, deep, Ironwood that carries over onto the door trim and console.

Round air vents, new for Super Duty, have notched gear-like surrounds that are more angular and defined. The design cue is carried throughout the interior on the console cup holders and seat sides, to a gauge cluster that is more organized and easier to read.

All models (XLT and above) feature chrome on the air vent rings and trim around the gauges and the cupholders. Chrome accents highlight both the large and smaller gauges in the cluster as well as the info center in the middle of the cluster. Tasteful touches of chrome are carried on to the door bezels and the console cover.

“Chrome is an American thing and a truck thing,” said Golden. “It’s very visible on the outside and we wanted to bring it inside as well.”

All-new door trim features dual map pockets that are better integrated into the interior. The doors have 360-degree pulls that are easy to grab when wearing gloves or when arms are loaded with things. The center console has been designed to hold file folders and will stow many laptop computers out of site, an asset for those who use Super Duty as a work site office.

The adjustable accelerator and brake pedals and available power mirrors are now integrated into the memory system. One touch of a button sets the pedals and mirrors to the specific programmed spot.

Auxiliary power points have been added to the front floor console, available with captain’s chairs, one on Regular Cab trucks and two on Super Cab and Crew Cab.

Super Duty’s tough, capable design is carried throughout the vehicle. A special “rib” design sets a theme for the entire truck. The ribs, inspired by the indentions molded into a toolbox or the side of a dump truck, are prominently featured on the airbag cover, along the bottom of the map pockets, along the seat side supports and at the bottom center of the steering wheel. Embossed “ribs” are found on the storage bin on top of the instrument panel and on the doorsills. The theme migrates to the exterior of the truck, on the tops of front and rear bumpers, creating as cohesive design.

More comfortable seats feature a host of new materials and bold, modern patterns. XL models seats are covered with a more durable fabric and XLT models get a new technical pattern on the cloth seats. XLT Sport models offer a two-tone option with Stone or Camel inserts with black bolsters.

An FX4 trim package, available for the first time on Super Duty, features cloth seats with a dotted technical pattern and contrasting white stitching. FX4 leather seats contrast smooth-leather seating surfaces with rugged grain bolsters and contrasting white stitching. King Ranch interiors wear new, darker, richer dark Chaparral leather.

Super Duty’s quiet, comfortable cabin provides the perfect climate to enjoy any one of the available sight and sound features, many found only on high-end luxury vehicles. All radios with CD players are MP3 capable and an auxiliary input jack for MP3 players is standard on all models.

Customers may want to play their MP3 players through the available Panasonic Audiophile, nine-speaker sound system with 6-disc, CD changer or watch the latest videos on the available rear-seat DVD entertainment system that features a large, roof-mounted 8-in. screen and comes with two sets of wireless headphones and remote control.

A new available DVD-based navigation system features one-disc coverage of the entire United States including Alaska and Hawaii. The system features voice activation and uses text-to-speech technology to read turn-by-turn travel directions, including street names, aloud in English, French and Spanish and features a wide, 6.5-in. touch screen that is sharper and much brighter than competitors units.

 

Redesigned climate control system delivers improved comfort

The 2008 Super Duty has an all-new totally redesigned climate control system. The new system has an improved, more balanced airflow and refined, quieter operation, improving cabin comfort

A more reliable, more durable, higher capacity compressor, is just one of the many components that contribute to the better performance of the A/C system, greatly improving time to comfort, pumping air out of the registers that is eight to 10 degrees cooler than the previous generation. Dual-zone electronic automatic temperature control (EATC) has now been extended for 2008 and is available on all series, standard on Lariat and King Ranch.

Improved hoses and fittings reduce leaks and loss of refrigerant, making the system both more efficient and more environmentally friendly. Floor ducts on all Crew Cab and Super Cab models now run under the seats out of site of the rear-seat passengers and provide better rear-seat heat and A/C dispersion.

The defrost nozzles were repositioned and redesigned for better performance. The new system clears the windshield two to three minutes faster on gasoline models with an improved defrosting pattern.

“The system clears the entire bottom of the windshield and moves up in a steady pattern,” said Tom Bennet, supervisor, Super Duty Climate Control. “You no longer get the widow’s peak that other systems create.”

The new system has also greatly improved side window defrosting. Providing more airflow to the side windows reduces the amount of fogging that often occurs in large vehicles. The 2008 Super Duty now adds this function on the heat setting as well.

Rapid Heat supplemental electric heater speeds interior comfort

Ford is now offering the Rapid Heat supplemental heating system for all diesel truck customers. The system augments the diesel trucks heater providing faster warm-up on cold mornings.

“Diesel truck owners will love this,” said Bennet. “They’ve come to expect a certain level of performance from their trucks. This system will surprise them.”

Offered for the first time in North America, the self-regulating heater integrates into the HVAC case, improving the temperature of the heater up to 18 degrees Fahrenheit at discharge.

 

Down Under Design

No part of the visible vehicle escaped the aesthetic treatment. For example, Super Duty now features an aluminized 409 stainless steel exhaust system to provide increased corrosion protection.

“We made sure that the customer will be treated to an exhaust system that will maintain its aesthetic quality for the lifetime of the vehicle,” said John Roberts. “When you’re paying 50,000 for a truck the last thing you want to see is bits of corrosion.”

 

Safety

Super Duty features standard driver and front passenger airbags with an airbag deactivation switch for the passenger side (not included on the Crew Cab. New door-mounted safety belts fit more comfortably and feature new retractors with smoother, faster operation.

A center three-point belt is added to the center position on Regular Cab and to the center of the rear seat on Super Cab. Super Duty also features child seat tethers for front passengers on Regular Cab and all rear seat positions on Super Cab and Crew Cab. BeltMinder™ delivers an audible beep reminding drivers to buckle up, while the available SecuriLock system which prohibits the starting of the vehicle without the key.

 

SPECIAL FEATURES

FOCUS ON REFINEMENT DELIVERS THE QUIETEST SUPER DUTY EVER, BOTH INSIDE AND OUT

• Class-exclusive Quiet Steel technology provides the base for Super Duty’s quiet interior.
• Unique rear bulkhead sound package improves interior quietness by eight percent
• Expandable gull wings in fender wells are among many innovative technologies that reduce engine and road noise
• Every component and system of Super Duty’s drivetrain and chassis has been optimized to reduce NVH
• New more powerful, 6.4-liter clean diesel is fine-tuned to further reduce noise vibration and harshness
• Exhaust system tuned for refined sound features the industry’s toughest hanging system for better off-road durability

The 2008 Super Duty delivers on new levels of quiet sophistication that truck customers have come to expect. Building on the precedents set by the F-150, Super Duty engineers have developed a vehicle that sets new standards for what customers will come to expect from a work truck.

“Customers are looking for higher levels of refinement,” said Peter Reyes, Super Duty Chief Engineer. “They want a truck that can work hard, yet be as refined as the luxury car they just climbed out of. They don’t want to suffer any penalties for having to get a big truck.”

 

Innovative technologies deliver luxury-level interior quietness

Super Duty does double duty, serving as everything from an on-site office to the cabin of a long-haul family cruiser. Either case necessitates the need for a rugged, tough interior that doesn’t compromise on quiet comfort. Super Duty engineers have incorporated a host of technologies, delivering luxury car-like sound quality.

“The goal was to deliver a “wow” factor,” said Giri Nammalwar, Super Duty Vehicle NVH Supervisor, “and give Super Duty customers a level of sophistication that’s unexpected, yet appreciated. We made sure we let in only the good sounds.”

Super Duty’s refined sound package utilizes Quiet Steel, a technology that has proven itself in the F-150. Quiet Steel, a composite laminated steel sheet, makes up the vehicle’s dash panel, and works with extra sound padding in the dash and floor to provide the foundation for Super Duty’s quiet cabin.

One of the measures used by NVH engineers to set goals for interior quietness is something known as the articulation index, or simply put, the ability to carry on a normal conversation with anyone, anywhere inside the cab.

Sound engineers increased Super Duty’s articulation index through the use of a unique sound damping back panel that works with the rest of the sound package to balance the levels of quietness throughout the cabin. This technology not only improves the articulation index, it creates the perfect environment for all occupants to better enjoy the available Panasonic Audiophile sound system and DVD video entertainment system.

“The back panel makes a substantial improvement,” said Nammalwar.” With the panel installed, the new cab is six to eight percent quieter than a regular cab without the technology.”

Attention to exterior detail further reduces wind and road noise

Delivering an exceptionally quiet cabin involves focusing on more than what’s going on inside the interior. Innovative engineering was utilized on the exterior areas as well to further isolate the cabin from intrusive wind and road noise

For example, expandable “gull wings” fit tightly inside the fenders just in front of the doors. These plastic panels are hemmed with a material that expands under heat in the paint oven during the curing process, effectively sealing the wings tightly to the fender and bulkhead. Working in conjunction with the Quiet Steel dash panel, the wings further reduce unwanted road and wind noise.

The vehicle’s redesigned climate control system relocates the mechanicals from the engine compartment to inside the interior compartment. This unique strategy reduces the number and size of the openings in the bulkhead, resulting in an improvement in interior quietness.

Thicker, 4.8 mm side glass, a revised steering column boot with improved sealing and an improved instrument panel seal (located between the top of the instrument panel and the windshield) reduce both wind and powertrain noise. Foam-filled A-pillars and C-Pillar stuffers muffle wind noise as it moves around the cabin and help balance out the sound package. Even Super Duty’s front air dam was tuned in the wind tunnel and revised to better control airflow around and under the vehicle.

 

Team-work results in a refined and balanced Powertrain and chassis

A quiet, confident ride involves much more than just a quiet interior. Peter Frantzeskakis, Vehicle Development Manager, led the development team on an eight-month journey, fine-tuning every aspect of Super Duty from front to back. Every department worked together with the NVH teams to optimize each component and system, finding the perfect balance between performance and refinement.

“The people in the NVH group have a lot of valuable experience and a lot of passion in the product,” said Frantzeskakis, “They really took it upon themselves to make the 2008 Super Duty the best yet.”

Special attention was focused on the 6.4-liter Powerstroke® diesel, fine-tuning the already-quiet state-of-the-art powerplant to further reduce NVH. For example, the valve covers were redesigned to minimize injector noise and the NV H team even recommended changes to such specifics as the micron fits of the piston rings to get just the right sound quality, further reducing diesel clatter.

“The Powertrain and NVH teams set very aggressive targets for exterior idle,” said Frantzeskakis. ” It’s a night and day difference over the previous model.”

The diesel’s high-tech sequential turbocharger system also came under the scrutiny of the NVH team. Extensive efforts went into the development of the system to insure quiet-smooth operation during both low-speed and high-speed operation.

Powertrain engineers and designers worked side-by-side, tuning the new air induction system and exhaust to give Super Duty its powerful, yet refined note, while a new engine mount further reduces idle NVH.

No issue was left unresolved. Ford’s NVH lab specialists were enlisted to help in eliminating a harmonic hum caused by the alignment of the engine’s cooling fan with the pulley’s turning behind it. The lab technicians helped design a special offset fan blade pattern that eliminated the hum without affecting the fan’s performance.

Shifting attention to the transmission, the team developed a new three-plate torque converter architecture that reduces idle NVH and improves shift quality. The transmission received all-new gear sets to reduce gear whine and the clutches were optimized to eliminate ticking by changing the groove pattern.

To further improve shift quality and reduce unwanted vibration, Super Duty uses a bellows-type center support bearing on the two-piece driveshaft, a first-time use on a heavy truck. The redesigned isolator vastly improves isolation at that joint

The eight-inch longer rear leaf springs were redesigned to better manage the torque as it moves to the rear of the vehicle. The springs feature stiffer front and rear bushings and a modified rear linkage to further increased stiffness and reduce vibration under acceleration.

 

Tough-truck exhaust designed for robust performance

The pleasing sound coming from the 2008 Super Duty’s exhaust system was specifically designed to represent tough truck capability with the refinement of a car. The team focused heavily on upgrading the acoustics of the exhaust system for a good overall sound from idle to full throttle.

“The muffler is our tuning device,” said John Roberts, exhaust supervisor,” In the end you want a smooth sound. You don’t want to hear a fluxuation in sound, but a linear transition.”

Computer-Aided Engineering (CAE) played an extensive role in the development of Super Duty’s exhaust system acoustics. Sound engineers “built” the sound of the muffler before prototypes were actually built and put on the vehicle. Working in this way presented the opportunity to develop a specific exhaust sound for each powertrain, further optimizing refinement.

“We would run hundreds of iterations of mufflers until we felt we had something that we should build,” said Roberts. “The prototype was used for confirmation.”

Roberts and his group also addressed the issue of cool-down ping. The Super Duty is the first Ford vehicle to utilize premium heat shields made of a multilayer sandwich of stamped stainless steel and aluminum. The shields create a very good sound barrier as well as provide excellent thermal protection.

The new exhaust system hangs from the toughest exhaust hangers in the industry. Large, 14-millimeter wire hangers, Torca clamps and bigger isolators have been designed for ease of serviceability and to better isolate the exhaust system, preventing it from moving around and causing unwanted squeaks and rattles.

“Our customers often take these vehicles off-road and the exhaust tended to move around,” said Roberts. “The new system holds everything firmly in place and in addition the structure is very robust. You could do chin-ups off of some of the hangers in this system. They’re that rigid.”

 

Multi-Objective Optimization

Super Duty’s high level of refinement can be attributed to a new strategy implemented by the development team. In the past, vehicle teams were divided by attributes, such as vehicle dynamics, ride and handling, noise vibration and harshness (NVH) and shift quality. Multi-Objective Optimization breaks down the walls between attributes, focusing on the entire vehicle.

“For us it’s about trying to optimize the vehicle for all the attributes, working together to develop the truck, to get the right refinement,” said Peter Frantzeskakis, Vehicle Development Manager. “It’s a lot more challenging to solve the problems, but the results are worth it.”

Frantzeskakis says that there are only a certain number of tuning parameters, and those parameters need to address all the attributes. The team worked up front to established the assessments to address all of the attributes. When one attribute was changed, the team could see how it would affect all the other attributes.

“You can also see how improvements to some systems can improve others,” said Frantzeskakis. “For example, the revised rear bushings not only helped improve the ride, but showed improvements in shift quality as well.’