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2004 FORD F-150 LAUNCHES A NEW ERA OF BUILT FORD TOUGH

The dominant force in pickups has just upped the ante.

Now, as it celebrates more than 85 years of truck experience and 55 years of legendary F-Series accomplishments, Ford is again redefining America's truck. The all-new 2004 Ford F-150 creates a bold first impression as it extends Ford's tradition as America's Tough Truck leader. It creates an even bigger lasting impression when its doors are opened to reveal a revolutionary interior design with refinement, comfort and spaciousness unparalleled in a truck.

The combination of Tough Truck capability and refinement sets a new standard for the industry. Toughness. Strength. Pulling Power. Fuel Economy. Safety. Interior spaciousness. Refinement. Driving dynamics. Stability. Functionality. Cargo capacity. Comfort. Style.

Ford pioneered the pickup, gave it the first V-8 engine and Crew Cab and went on to create a brand that is synonymous with truck leadership. Tough, capable and powerful, the F-Series has been the best-selling full-size pickup for 26 years as of January 2003 and the nation's favorite vehicle for 21 years running. The Ford F-Series is America's truck.

COMPREHENSIVE 3-CAB, 3-BOX, 5-SERIES LINEUP

F-150 now offers the industry's widest variety of body and trim configurations. Customers can specify the pickup box according to load length and box style, with more choices than ever before. Additionally, all cab configurations now feature four doors for ease of access. The lineup includes:

Three cab choices-
- Regular Cab , a single row of occupant seating and rearward-swinging access doors that reveal a behind-seat stowage area up to 13 inches wide.
- SuperCab , a two-door extended cab version featuring a second row of seating accessed by two rearward-swinging doors.
- SuperCrew , a crew cab that features two rows of seating and four forward-swinging full-size doors.
Three box lengths and two box styles -
- Eight-foot , 6 1/2-foot, and 51/2-foot box lengths are offered. In addition, the F-150 SuperCab 5 ½- foot box is a new offering and a full-size pickup truck exclusive.
- Two different box styles , Styleside and Flareside, are available.
Five distinct series offerings -
- From the workhorse F-150 XL to the refined F-150 Lariat, the 2004 F-150 lineup has the truck to meet a variety of customer wants and needs. The five series - XL, STX, XLT, FX4 and Lariat - each reflect insight into unique customer needs.

ALL-NEW TOUGH TRUCK DESIGN IS SOPHISTICATED, ASSURED

The all-new F-150 exterior is designed to be confident, powerful, fresh and refined. Drawing on design elements from the current F-150, the F-Series Super Duty lineup and the Mighty F-350 TONKA concept, the new truck's taut, boldly chiseled shape resonates Ford Tough Truck tradition.

"Creating an all-new F-150 was about asserting the toughness and truck capability of the leader," said Patrick Schiavone, design director, Ford Tough Trucks.

"We definitely wanted to push the design to a new level, to move the excitement needle up a notch. The result is a shape symbolic of strength with an underlying tone of sophistication that really gives this truck aspirational qualities," Schiavone said.

Tall-shouldered and proud, the new F-150 profile features a self-assured, "planted" stance achieved through widening the front and rear tracks more than 1.5 inches. New larger standard wheel and tire combinations reside in straightforward circular wheel arches that visually communicate power.

The bold front-end design conveys strength and symbolizes the powerful engine range. It features new quad-circle-styled headlamps designed in form-follows-function clusters, and incorporates a new wrap-around fascia treatment that communicates refined sophistication and precision. A bold bumper with integral foglamps, when equipped, and tow hooks (on 4x4 models) complete the look.

Enhancing the truck's visual strength is its high beltline, which draws attention to its chiseled, powerful flanks and a roofline reminiscent of chopped-top custom street trucks. A more vertical tumblehome (the inward bow of the side windows) balances the visual weight of the lower body while allowing nearly flush side glass, a mark of refinement. The doors adopt the Ford signature stepped-down beltline - a feature that aids outward visibility while providing an athletic rake that dynamically links the front and rear of the truck.

MORE ROOM FOR PEOPLE AND THEIR CARGO

The passenger compartment of the Regular Cab and SuperCab body styles is 6 inches longer, giving customers greater interior spaciousness. Regular Cab models feature industry-first rearward-swinging access doors that make it easier to reach a behind-seat cargo area that is large enough for golf clubs, toolboxes or five-gallon paint buckets. Each access door features an integral window that contributes to the airy, spacious interior feel of the new F-150. SuperCab occupants can enjoy first-in-class rear door power windows (on XLT, FX4 and Lariat) as well as an optional power sliding rear window.

The clean look of the F-150 Styleside box is available in all three box lengths - 8-foot, 6 1/2-foot and 51/2-foot. F-150's new 61/2-foot Flareside box - formed of inner steel panels and sheet molded composite exterior panels - is available on STX, XLT and FX4 models. The stylish Flareside harks back to historic Ford models with deeper, fender-like wheel flares and a unique tailgate design that flares outward at its upper edge for a "spoiler effect." Tailgates for both box designs incorporate Ford's new Tailgate Assist, an innovative and segment-exclusive feature that reduces opening and closing efforts.

REVOLUTIONARY NEW INTERIOR DESIGN

The 2004 Ford F-150 interior sets new standards for craftsmanship and refinement. It reflects Ford's attention to detail and provides enhanced occupant comfort, reduced interior noise and more feature content.

"Truck owners spend more time than ever before in their vehicles, both for work and personal use," said Jim Smithbauer, F-150 design manager. "We designed the new F-150 interior to give them the comfort, craftsmanship, versatility and features they want and deserve. The look is very modern, precise and industrial, and it's executed in an honest, straightforward way."

Designers adopted a modular approach when creating the F-150 instrument panel. Bold vertical bands gave the design team tremendous flexibility to adopt different colors, textures and materials to customize the look of the instrument panel. All models, including the base version, feature an attractive two-tone instrument panel.

Designers created three different instrument cluster designs, which combine with other elements to give each series a distinctive look. For example, the FX4 cluster evokes images of classic aviation while the Lariat features chrome-ringed gauges that match other chrome interior elements, including the door handles.

Functional round air registers are trimmed in chrome on higher-specification models and are dimpled for fingertip-controlled opening and closing.

The new F-150 interior introduces a flow-through center console, giving customers the option of two captain's chairs with a floor shifter on FX4 and Lariat models. The floor shifter, another F-150 first, is a sophisticated design, detailed in warm steel and chrome. Vehicles equipped with a 40/20/40 split-front-bench seat have a different instrument panel center stack optimized for middle passenger legroom.

The new F-150 marks the debut of another industry-first - a modular overhead rail system that allows owners to customize interior storage options to suit their individual needs. It is standard equipment on XLT, FX4 and Lariat SuperCab and SuperCrew models.

The brushed aluminum rail system is integrated into the headliner and extends from behind the rearview mirror to behind the second row of seats. The forward end of the rail features a dome light console and a large storage bin module.

The system - with integral power supply - allows owners to easily snap in additional modules, such as first aid kits, toolboxes, flashlights and two-way radio holders as they become available from Ford or the aftermarket. Already available on XLT, FX4 and Lariat SuperCrew is an optional rear-seat DVD entertainment system.

THE NEW, DIFFERENTIATED F-150 FAMILY

In order to meet the needs of key customer segments, Ford developed five distinct models for the new F-150. Each series provides new attributes and comfort and convenience features - many of which are firsts in the full-size segment.

"In essence, we are reinventing the rules in the full-size pickup market," said Doug Scott, Ford Division truck group marketing manager. "We built on our heritage, listened to customer feedback, and developed a totally new approach that allows us to appeal to the full-size truck market and provide individualized versatility and character."

F-150 XL

The XL personifies the pickup's role in building America. It is the workhorse truck that gets the job done, and can get down and dirty with hose-out floor functionality. The XL is available in both Regular Cab and SuperCab models with a choice of vinyl or cloth interior. The Regular Cab configuration is equipped with Ford's new rear access doors, which open up a more spacious area behind the 40/20/40 split-bench seat for stowage. The XL boasts a bold, forthright grille design; tailgate-assist; and larger, standard 17-inch steel wheels. New features also include standard tilt steering wheel and a center display system in the instrument panel.

F-150 STX

The F-150 STX provides work truck capabilities in a sporty, stylish package. STX, powered by the 4.6-liter Triton™ V-8 engine, is available in Regular Cab or SuperCab body styles and features body-color bumpers and 17-inch sporty cast aluminum wheels. STX comes equipped with a standard 61/2 -foot Styleside or an optional Flareside box, and the SuperCab model also offers a 51/2 -foot Styleside box option. Owners of the new STX can opt for an available audiophile sound system with AM/FM radio and 6-disc CD changer with subwoofer.

F-150 XLT

Versatile enough to carry people and cargo, the XLT series is ideal for a wide array of uses - ranging from hauling to recreation. XLT is available in all cab variations and, depending on cab choice, all three Styleside box lengths and Flareside configurations are available. XLT features an optional Silver two-tone paint finish, unique grille treatment and standard 17-inch cast aluminum wheels. Premium cloth is featured on the standard 40/20/40 split-bench seat or optional dual captain's chairs, and a chrome instrument panel accents add distinction. The XLT features Ford's new overhead rail system and foglamps on 4x4 models. For SuperCab and SuperCrew models, XLT's standard second-row power windows are a segment first.

F-150 FX4

The new FX4 is aimed at outdoor enthusiasts who believe four-wheel-drive capability is a critical lifestyle element. It combines off-road capability with a bold and distinctive individual statement. FX4 models are available in Regular Cab, SuperCab and SuperCrew body styles. Customers have a choice of box configurations: 61/2-foot Styleside, 61/2-foot Flareside or the new 51/2-foot Styleside, depending on cab choice. New optional 18-inch machined cast aluminum wheels, body-color bumpers, a distinctive grille and a new available Dark Shadow Gray lower two-tone exterior paint treatment complete the package. Inside, FX4 has unique "warm steel" accents on the instrument panel, center console, doors and steering wheel. Its aircraft-inspired instrument cluster, "carbon mesh" accents and chrome-ringed air registers further refine the look. Optional captain's chairs can be specified in either sporty cloth or sporty leather, and come with a segment-first, flow-through center console with floor shifter.

F-150 LARIAT

The ultimate in truck refinement, the F-150 Lariat combines truck toughness and comfort, geared to buyers who view their trucks as a reward for achievement. Lariat owners use their trucks for a multitude of purposes from everyday driving and road trips, to towing boats or travel trailers. Many depend on their trucks for towing but want comfort and refinement. The Lariat features optional premium heated dual power leather captain's chairs with the unique flow-through console and floor shifter or a standard 40/20/40 leather split bench seat. The instrument panel and center console contain finely crafted stitched surfaces in Medium Pebble or Ebony, augmented by woodgrain touches on the doors and instrument panel center stack. Lariat's instrument cluster also is unique, with cream-colored gauges ringed in chrome to complement the chrome-ringed air registers and chrome door handles. The steering wheel has built-in controls for key audio and climate control functions. Other special Lariat features include an in-dash message center, electronic automatic temperature control and power-adjustable memory seats and pedals. An available Beige lower two-tone paint treatment, chrome bumpers and a unique grille, along with 18-inch bright aluminum wheels accentuate the exterior.

SUPERIOR DRIVING EXPERIENCE

The all-new Ford F-150 provides an entirely new driving experience in a full-size pickup. The steering is crisp and direct, the ride is plush yet controlled, the braking is strong and assured, and the cabin is quiet. Ford has applied its expertise in driving dynamics to the best-selling vehicle in the world, and the result is a pickup truck that is responsive, confident while towing and robust and capable off-road.

The new F-150 has been designed to achieve exceptional handling, ride and quietness due in part to a solid and stable fully boxed frame with hydroformed front rails. The frame is approximately nine times stiffer in torsion and approximately 50-percent stiffer in bending as the already robust backbone of the current truck.

The entire frame is fully boxed to form a closed "box" section rather than the traditional "C" rail design, and hydroforming was used for the sections of the frame rails that bear the loads of the front suspension. The result is increased stiffness and stronger attachment points for the brackets that attach the body and suspension to the frame - and minimal shake and shudder on rough roads.

With a driving feel that is designed to be plush yet connected to the road, F-150 has a front suspension system that readily absorbs bumps but stands strong against steering forces. Both 4x2 and 4x4 models use new coil-on-shock, long-spindle, double wishbone front suspension with cast aluminum lower control arms - a first in the pickup truck segment. The suspension reduces unsprung weight to help provide better ride and stability on choppy, broken surfaces.

Advanced bushings - soft in response to road impacts but stiff to cornering loads, with ride tuning and handling tuning optimized independently - contribute to the improved ride and handling. Engineers targeted crisp steering response with new features including "gripping" bushings and double ball-type joints instead of rubber bushings in the stabilizer bar system.

The front shock absorbers are mounted inside the springs, allowing four-wheel-drive models to use coil springs instead of the traditional torsion bars, permitting more precise suspension tuning and commonality across the lineup. The design also moves the shock absorber closer to the wheel for approximately 25-percent greater mechanical advantage, which allows for more precise shock tuning.

The Hotchkiss-design rear suspension has been optimized with rear shock absorbers placed outboard of the frame rails - a segment exclusive - for improved control of body lean and a smoother ride. The shock position also provides better control of axle "skipping" and "skating" that can happen on washboard-type surfaces. Rear leaf springs are now 3 inches wide (20 percent bigger than the 2002 F-150 and the same width as on the F-Series Super Duty lineup) to help reduce sway during cornering and considerably improve towing stability.

A rack-and-pinion steering system that is the largest and strongest ever used on a Ford vehicle was engineered to provide improved steering response for the new F-150. It is more robust than the recirculating-ball system used on the current F-150 and has less operating friction. Both measures contribute to the precise steering response that makes the new F-150 driving experience spirited and confidence-inspiring.

"Steering response was a top priority for our dynamics team because this is where the vehicle communicates very directly to the driver," said Frank Davis, F-150 chief program engineer. "The new rack-and-pinion steering, increased system stiffness and reduced friction all play their part in delivering a superior driving experience."

In addition to its class-leading dynamic performance, the new F-150 steering system also makes for a relatively tight 46-foot turning circle on SuperCab models with the 61/2 -foot cargo box, which beats comparably equipped competitors, most notably the Dodge Ram Quad Cab. The new standard four-wheel disc brakes are larger and more powerful while providing better feel.

The rotors are larger and thicker, and the calipers are larger and even more robust - 60 percent stiffer - for enhanced stopping power and better brake pedal "feel." Four-wheel anti-lock brake control (ABS) and electronic brake force distribution (EBD) are standard.

The vented front discs have twin-piston calipers and are 330 millimeters (13 inches) in diameter, an increase of 22 millimeters (0.87 inches), or about 7 percent. The vented rear discs, with single-piston calipers, have a diameter of 348 millimeters (13.7 inches), an increase of 14 millimeters (0.55 inches). Increasing rotor size provides more surface area for brake pad contact and better heat dissipation for more consistent braking performance in stop-and-go driving or while towing.

The F-150 suspension is designed to contribute to braking assurance, resisting body dive and counteracting natural toe-out forces under braking to provide the driver predictable, consistent stopping performance.

While the most dramatic improvement in the F-150 driving experience comes on-road, Ford has steadily improved off-pavement performance. Four-wheel-drive models use the proven manual- or electronic shift-on-the-fly transfer case of the current F-150 and a selection of optional limited-slip rear axles.

In low range, electronic throttle control allowed engineers to incorporate a dedicated accelerator response strategy for better control of torque in the most challenging and slippery conditions.

Off-road braking performance was the subject of careful tuning. On loose surfaces like gravel, F-150 engineers were able to improve off-road stopping distances by approximately 13 percent.

For the most serious off-road enthusiasts, the F-150 FX4 provides skid plates, specifically tuned shock absorbers, optional LT tires and a standard limited-slip 3.73:1 rear axle.

REFINED POWER

The new F-150 offers two engine choices - a 5.4-liter, 3-valve Triton ™ V-8 and a 4.6-liter Triton ™ V-8.

The all-new 5.4-liter, 3-valve Triton ™ V-8 engine is designed with three valves per cylinder, variable cam timing and a host of other features that provide increased power - especially at low engine speeds - along with improved refinement and efficiency.

The new engine delivers 300 horsepower at 5,000 rpm and 365 foot-pounds of torque at 3,750 rpm. The all-new, aluminum cylinder head - with two intake valves and one exhaust valve per cylinder for 24 valves in total - and an improved cast-iron block balance impressive power with better fuel efficiency and quieter operation.

This new technology builds on Ford's proven modular V-8 engine platform. Its predecessor, a 2-valve version of the 5.4-liter Triton ™ , has been named to Ward's 10-Best Engines list six years running. It isn't a single technology but rather a suite of enhancements that deliver these consumer benefits.

The new engine will be Ford's first modular V-8 to use variable cam timing, which allows Ford engineers to optimize intake and exhaust valve actuation across the engine speed range. It is the industry's first mass application of dual-equal variable-cam timing, which shifts the intake and exhaust valve timing together.

Variable camshaft timing allows the valves to be operated at different points in the combustion cycle, to provide performance that is precisely tailored to specific engine speed and load at that instant. The driver does not notice that the cams are changing, but recognizes that there's more power when it is needed.

In combination with precise control of spark timing, fuel injection and use of electrically controlled Charge Motion Control Valves in the intake runners, this technology produces improved power and torque, particularly at the lower engine speeds that are so important to applications such as towing and heavy hauling.

With all-aluminum heads, single overhead camshafts, magnesium camshaft covers and a clean-sheet design approach, Ford's engineers were able to develop a three-valve-per-cylinder engine that has virtually no weight penalty compared with two-valve V-8 engines. The three-valve head is dimensionally smaller than the two-valve design for the 5.4-liter engine, while offering more rigidity and strength. It also is easier to manufacture.

At lower speeds and lighter loads, the new Charge Motion Control Valves (CMCV) - located at the end of each intake runner - are specially shaped to speed up the intake charge and induce a tumble effect in the combustion cylinder. This causes the fuel to mix more thoroughly, and to burn quickly and efficiently, with reduced emissions, particularly at idle.

The CMCVs are controlled by an electronic motor, and open at a predetermined point as engine speed increases. At higher engine speeds, they do not affect the intake charge at all. This allows undisturbed maximum flow into the combustion chambers at wide-open throttle.

New on both the 5.4-liter and 4.6-liter engines is a segment-first torque-based electronic throttle control that uses driver input from the accelerator pedal to actively modulate the torque at the drive wheels. It is a direct descendant of technology first used in fighter aircraft.

Replacing the mechanical throttle linkage is an accelerator position sensor, an electronic control circuit and an actuator at the throttle valve on the engine. The controller takes into account the current operating status of the engine and ambient conditions, and then operates the throttle as needed to best deliver the desired result.

This produces seamless and consistent engine response, improved fuel economy and enhanced integration of vehicle systems, such as the transmission, variable camshaft timing, vehicle speed control and idle speed control.

IMPROVED 4.6-LITER TRITON TM V-8

Also available in the new F-150 is the 4.6-liter Triton ™ V-8. It achieves 231 horsepower at 4,750 rpm and an impressive 293 foot-pounds of torque at 3,500 rpm. Ninety percent of this torque is available at 2,000 rpm for strong towing performance and solid acceleration while hauling heavy loads.

In addition to the benefits of the new electronic throttle control system, the 4.6-liter modular V-8 has reduced hydrocarbon emissions for 2004 thanks to improved gaskets, seals and crankcase-ventilation plumbing.

The 4.6-liter Triton ™ V-8 has two valves per cylinder and a cast iron block. It uses an upgraded version of Ford's 4R70E four-speed automatic transmission, which has improved shifting controls, for smoother performance.

ENHANCED AUTOMATIC TRANSMISSIONS

Matched to the new 5.4-liter, 3-valve Triton ™ V-8 is a new 4R75E four-speed automatic transmission, an evolution of the 4R70E used on the current F-150. It is upgraded to handle the torque of the 5.4-liter engine, while taking advantage of patented upgrades to the 4R70E.

While final certification is not yet complete, Ford expects the new F-150 will offer competitive fuel economy.

The new 5.4-liter, 3-valve Triton ™ V-8 meets the U.S. federal government's Tier 2, Bin 5 Emission Vehicle standard. The 4.6-liter Triton ™ V-8 meets the Tier 2, Bin 10 Emission Vehicle standard.

CAPABILITY, COMFORT AND CONVENIENCE

Tough, capable and versatile, America's pickup truck also has more interior spaciousness, features that contribute to ergonomic ease and new levels of refinement. The combination makes for a calm, quiet confidence that all drivers will appreciate.

Each of F-150's cargo boxes - offered in 51/2-, 61/2- and 8-foot lengths - is more than 2 inches deeper than before, increasing usable volume. The total cargo volume of the 61/2 -foot box, for example, is 65 cubic feet, which is nearly 12 percent better than the current F-150, 13 percent better than Chevrolet and 42 percent larger than Toyota's 6-foot box. That extra capacity could save a trip to the landscape supply or garden center.

The newly engineered chassis and seamless powertrains make pulling a trailer easier than ever. The 5.4-liter, 3-valve Triton™ V-8 has excellent torque at lower engine speeds, and its sophisticated electronic throttle control provides seamless, instant response and consistent transmission shift quality. Four axle ratios - from 3.31:1 to 4.10:1 - are available, and all but the 3:31:1 can have optional limited-slip capability for enhanced traction.

The laterally stiff new rear suspension is very resistant to side loads, so trailer influence on the truck (in crosswinds, on rutted roads or alongside 18-wheelers) is minimal. This contributes to confident, stress-free trailering, aided by powerful new braking capability.

With a maximum tow rating of 9,900 pounds and maximum payload capacity of 3,000 pounds, the new F-150 is the most capable full-size pickup under 8,500 pounds.

At F-150's core is a stout, fully boxed ladder frame with hydroformed front rails. Critical cross members are welded to the rails with a "through-rail" joint to prevent localized flex. "Wide-footprint" brackets attach the suspension, body and powertrain to the frame to maximize the strength of the attachment point. The entire frame is welded together, built to last.

The new body structure is improved by more than 75 percent and works with the stiffer frame to ward off squeaks and rattles. For the new F-150, the most aggressive use yet of structural adhesives on a Ford truck helps to spread loads over the length of a seam, to maintain long-term body stiffness.

Prototypes completed a 17-week corrosion test at Ford's Arizona Proving Ground that included a gamut of torture, including Salt Bath, Humidity Chamber and Drying Chamber. Sixty cycles of this testing simulate six years of abuse in Canada's rugged Maritime Provinces. Today's F-150 prototypes were subjected to hundreds of testing cycles.

In addition, the new F-150 has endured the equivalent of more than 5 million cumulative miles of engine testing.

Contractors and personal-use buyers may have different needs and wants in their F-150, but they all use the truck as a tool - to get the job done, to get their gear to the recreation area or to get to work between weekends. Ford knows that any good tool is easy to use, and has worked extensively to help ensure that all of its customers find F-150 a good "fit."

People come in all shapes and sizes, of course, and the F-150 reflects that fact: It's designed to accommodate a so-called 25th-percentile woman (approximately 4'10" tall) as well as a 99th-percentile male (approximately 6'4"). The cabin is wider than ever before and its front seat is roomier, yet the door armrests extend far enough for smaller drivers to use comfortably. Grab handles and optional running boards assist during entry and exit, and optional power-adjustable pedals join a standard tilt steering wheel for customizing the driving position.

A standard Tailgate Assist feature uses an internal torsion bar to help with raising and lowering the tailgate. The optional running boards were moved lower and farther outboard to be more useful for stepping up into the cab.

Essential to meeting Ford's goals for the best driving experience available in a pickup truck was engineering quietness into the cabin. A quiet passenger cabin helps driver and passengers to stay alert and arrive relaxed, and has a profound effect on customer satisfaction.

The F-150 team tackled cabin noise with fanatical attention to detail.

During wide-open-throttle acceleration, the "speech articulation index" - a measure of how easily one can hold a conversation - is 5 percentage points better than the nearest competitor, above 3,500 rpm.

Liquid-filled engine mounts or "hydromounts" attenuate much of the engine's noise and vibration before it can reach the passenger compartment. To further combat unwanted noise, the new F-150 has inset doors with improved seals, thicker front side windows, a laminated dash panel and noise-blocking air extractor vents at the rear of the cab. New double door seals contribute to the quiet ride.

SAFETY AND SECURITY

The all-new Ford F-150 has been engineered with a focus on safety. Across the line-up, the new full-size truck from the Tough Truck leader has the strength, technology and know-how to protect its occupants.

The new F-150 helps to protect its occupants with a structure designed to absorb crash energy and dissipate it before it can reach the reinforced passenger compartment. In the U.S. Federal Government's frontal crash tests, the 2002 F-150 SuperCrew scored five stars for driver and front passenger protection.

In the Insurance Institute for Highway Safety's offset frontal crash test, Ford expects the new F-150 to earn high marks, based on extensive internal testing. It also has been designed to meet the new Federal Motor Vehicle Safety Standard (FMVSS) 208, which regulates air bag as well as offset crash performance.

The new, strong hydroformed front frame rails are built with computer-designed front horns to help manage crash forces. In an impact, these areas of the frame are designed to collapse in an accordion fashion, dissipating energy before it reaches the passenger compartment.

Innovative design added additional space to this crush zone. Rather than being welded or bolted to the back of the fully boxed bumper beam, the front frame rails extend through cutouts in the beam to its front face, where they are welded in place. In a severe frontal impact, lower suspension control arms are designed to fracture, further absorbing crash energy.

The front crush structure is built from channeled steel sections welded together to form fully boxed frame rails. These sections meet the robust hydroformed frame ahead of the cab, providing a rugged steel platform beneath the entire passenger compartment. Reinforcements on the frame rails further improve the frame stiffness there. Combined with exceptionally stiff door sills and door openings, the hydroformed frame is able to help keep the main section of the frame from twisting during an offset crash. In the U.S. Federal Government's side impact tests, the new F-150 is designed to retain its strong performance.

The new F-150's portfolio of safety features now includes the Ford Personal Safety System ™ and new occupant sensing technology.

With Personal Safety System ™ , frontal air bags offer multiple deployment levels to tailor inflation force to the severity of the crash, the driver's safety belt use and the driver's seat position, as determined by a sensor mounted to the seat track.

The Personal Safety System ™ is augmented by advanced passenger-weight-sensing technology. If the sensor detects no weight on the front passenger seat - or very little weight, such as a newspaper, a half-dozen bagels or work gloves - the passenger-side air bag is automatically turned off. If more weight is detected on the seat, as with a small child, the air bag remains turned off and a light on the instrument panel illuminates with the message "PASSENGER AIR BAG OFF." If an adult is seated properly in the passenger seat, the light is extinguished and the air bag is automatically switched on. Small children should always be seated in proper supplemental safety seats in the rear seats whenever possible, even with this system.

A vehicle occupant's best line of defense in crashes remains the safety belt. The new F-150 has three-point belts at all outboard seating positions and all rear seating positions in SuperCab and SuperCrew. To encourage safety belt use, the new F-150 is equipped with Ford's pioneering BeltMinder ™ system, which prompts the driver and - for the first time in a truck - the front passenger to buckle up.

At both the driver and outboard front passenger positions, safety belts are equipped with pyrotechnic pretensioners and load-limiting retractors. In the first moments of a frontal impact, the pretensioners pull the lap and shoulder belts tighter, which helps to reduce slack in the belts.

The new F-150 has standard provisions for safely securing a LATCH-compatible child safety seat. There are three sets of LATCH (Lower Anchors and Tethers for Children) fixtures and top tether anchors across the rear seat of SuperCab and SuperCrew models, and a top tether anchor on the front passenger seat. Regular Cab models have both LATCH lower anchors and a top tether anchor on front passenger seats.

Numerous additional features help to protect customers, the new F-150 and its contents, including Ford's patented SecuriLock™ passive anti-theft system, available keypad entry, remote keyless entry, spare wheel lock and standard lockable tailgate.

With 6 more inches of interior cab length on Regular Cab and SuperCab models, the F-150 provides more lockable stowage volume than ever before - up to 13 inches behind the front seat of the Regular Cab.

THE F-SERIES LEADERSHIP STORY

The story of the Ford F-Series is one of sustained leadership. From the construction site to the house next door, the full-size pickup has earned its place in the fabric of American life. F-Series is America's choice. It outsells every other full-size truck brand. In fact, F-Series has been America's favorite vehicle for 21 years running, as of January 2003.

Historically, Ford has led the industry with innovations such as a standard third door on SuperCab and the SuperCrew. These configurations gave F-Series customers true personal-use versatility - without compromising tough truck capability. When extended cab models were introduced in the 1990s, they accounted for less than 20 percent of the total market. Today, they represent approximately 80 percent of sales due to their increased passenger space and functionality.

"Ford's F-Series leadership is well documented," said Matt DeMars, executive director for Tough Trucks, Ford Motor Company. "We have a huge owner base and a reputation for toughness and durability that is unsurpassed in the industry. We used our customer insight to help us anticipate the 'next big thing' in the market, and we continue to give customers in this growing segment the most appealing products."

In 2002, Ford dealers delivered more than 800,000 F-Series trucks to U.S. customers, making F-Series America's best-selling truck for the 26th consecutive year.

The numbers tell why Ford is aggressively striving to maintain and extend its leadership as the best-selling full-size pickup. The F-Series is extremely important to Ford's bottom line. It accounts for nearly 28 percent of Ford Division's sales and 23 percent of Ford Motor Company's total U.S. sales.

SUPERIOR DRIVING EXPERIENCE

The all-new Ford F-150 delivers crisp and direct steering, the ride is plush yet controlled, the braking is assured and the cabin is quiet. Ford has brought its expertise in driving dynamics to F-Series, the best-selling vehicle in the world, and the result is a pickup truck that is an unqualified pleasure to drive.

A SOLID FRAME, HYDROFORMED AND FULLY BOXED

Essential to meeting the driving dynamics targets for the new F-150 is a solid and stable fully boxed frame with hydroformed front rails. It is approximately nine times stiffer in torsion and approximately 50-percent stiffer in bending than the current truck's already robust backbone.

A stiff frame is the enabler for the new F-150's handling, ride and quietness. A frame that twists, bends or shakes excessively over bumps or while cornering would limit the ability of the suspension system to damp the input and therefore transmits vibration to the passenger compartment.

While hydroforming is used for the sections of the frame rails that bear the loads of the front suspension, the entire frame also is fully boxed to form a closed "box" section as opposed to the traditional "C" rail design. The result is increased stiffness and stronger attachment points for the brackets that attach the body and suspension to the frame - and minimal shake and shudder on rough roads.

Advanced computer tools played a pivotal role in the design of F-150's backbone, according to Anthony Selley, F-150 chassis supervisor.

Digital three-dimensional representations of the frame, powertrain, suspension and body were run through deflection simulations that exaggerate actual movements by a factor of 50, to reveal areas that may need attention.

"We were exploring thousands of design options at once," said Selley. "The only way to do this is with computer-aided engineering. CAE allowed us to weigh all the options before we actually built the designs and subjected them to instrumented testing."

NEW SUSPENSION OFFERS IMPROVED RIDE

A substantial contributor to the new F-150's driving feel - plush, yet connected to road - is a front suspension system that reacts and absorbs bumps but stands strong against steering forces. Both 4x2 and 4x4 models use a new coil-over-shock, long-spindle double wishbone front suspension with a cast aluminum lower control arm.

The use of cast aluminum is a first in the pickup truck segment, and by reducing "unsprung weight" (the parts of the suspension system that must move up and down with road irregularities) the aluminum lower control arm provides better ride and stability on choppy, broken surfaces.

The front bushings are soft in response to road impacts but stiff for cornering capability, with ride tuning and handling tuning optimized independently. The ratio of lateral to longitudinal response of the aft lower control arm bushings is 29 to 1, which betters many performance sedans. Much of the all-new F-150's previously unattainable combination of ride and handling comes from these subtle details.

F-150 engineers selected new "gripping" bushings to mount the front stabilizer bar. This novel design keeps the bushing compressed against the stabilizer bar, allowing the bushings to twist with it. The special design gives more linear loading for "crisper" steering response, yet maintains relatively low bushing rates for a smooth ride.

The stabilizer bar ends use ball joints at both ends instead of rubber bushings, which further reduces compliance in the stabilizer bar system, providing for improved response.

Mounting the shock absorber inside the coil spring is a packaging solution that allows four-wheel-drive models to use coil springs, permitting more precise suspension tuning and commonality across the lineup. In addition, the shock absorber has been moved closer to the wheel, providing increased mechanical advantage of approximately 25 percent.

For increased stability and a more aggressive stance, the front track is 67.0 inches wide - an increase of 1.6 inches over the current F-150. In addition, the scrub radius of the front suspension has been reduced, which helps increase stability while braking, reduces tire wear and enhances handling and steering precision.

OPTIMIZED REAR SUSPENSION

F-150's Hotchkiss-design rear suspension has been optimized with rear shock absorbers placed outboard of the frame rails - a segment exclusive. The shocks are positioned to maximize their effect at reducing the amount the truck leans, particularly during transitions like lane changes. They also provide better control of the axle "skipping" and "skating" that can happen on washboard-type surfaces.

In any live-axle rear suspension, the two shock absorbers work in tandem to damp the vertical motion of the wheels when the truck traverses irregularities such as speed bumps.

When the axle rolls in relation to the truck - when cornering or hitting a pothole, for example - the shocks also damp the axle's movement, but are typically compromised by being located near the centerline of the vehicle, where the shocks have little "leverage" against the axle. This results in impact harshness, because the shocks need to be stiffened to compensate.

The new F-150's outboard rear shocks maximize the amount of leverage against lean - and because of this massive leverage advantage, the shocks can be tuned for a smoother ride.

The rear leaf springs, which in addition to supporting the vehicle and its cargo also serve to locate the axle side-to-side and front-to-rear, are now 3 inches wide (20 percent wider than the current F-150 and the same width as on the Super Duty lineup) for less lateral motion during cornering and considerably better towing stability and controllability. Also contributing to the performance of the rear suspension is a track that is more than 1.5 inches wider than on the current model.

PRECISE NEW RACK-AND-PINION POWER STEERING

Improved steering response was a critical element in the engineering team's goal of providing the new F-150 with good dynamics. To achieve the targets for on-center feel, steering response and precision, the team chose a rack-and-pinion steering system that is the largest, strongest and most rugged ever used by Ford. It is considerably stiffer than the recirculating-ball system used on the current F-150, and it has less operating friction. Both measures contribute to the accurate steering response and better driver feedback that makes the new F-150's drive experience spirited and confidence-inspiring.

The predictable, linear response of the steering comes from careful tuning by experienced engineers to help ensure that steering effort builds naturally with steering angle, and that response matches angle and effort.

"You interact with the steering wheel for the entire time you are driving, and that interaction reveals more about the vehicle than anything else. As with the Ford Focus, the Escape, the Explorer and the Expedition, the steering wheel of the F-150 immediately communicates the performance potential of the vehicle," said Dan Gompper, F-150 vehicle dynamics supervisor.

In addition to its dynamic performance, the new F-150's steering system also makes for a relatively tight 46-foot turning circle on SuperCab models with the 61/2-foot cargo box, which beats comparably equipped competitors. The F-150 SuperCrew has a smaller turning circle than the Dodge Ram Quad Cab.

For the first time, F-150 has two steering rack ratios matched to the available wheelbases, which helps to provide a common steering feel across the model range.

MORE POWERFUL BRAKES

New standard four-wheel disc brakes are larger and more powerful while providing better feel. The rotors are larger and thicker and the calipers are larger and even more robust - 60 percent stiffer - for enhanced stopping power and better brake pedal "feel." Four-wheel anti-lock control (ABS) and electronic brake force distribution (EBD) are standard.

As with the communicative steering, experienced engineers tuned the brake system for a natural, confidence-inspiring feel. Short pedal travel, reduced efforts and lack of any "dead zone" as the brakes are applied are prerequisites to good brake feel.

Linear response of the pedal - in which force felt by the driver increases in direct proportion to the pedal travel - and linear vehicle deceleration are additional benefits the new F-150 brakes provide.

The brake pads are made of high-friction semi-metallic lining material that helps provide increased stopping power. By going to a higher friction pad, engineers were able to fine-tune pedal feel by tailoring boost from the power brakes. This provides a linear stopping rate that is proportional to the amount of pedal force being applied.

The vented front discs have twin-piston calipers and are 330 millimeters (13 inches) in diameter, an increase of 22 millimeters (0.87 inches), or approximately 7 percent. The vented rear discs, with single-piston calipers, have a diameter of 348 millimeters (13.7 inches), an increase of 14 millimeters (0.55 inches). Increasing rotor size provides more surface area for brake pad contact, more powerful braking and better heat dissipation for more consistent braking performance in stop-and-go driving or while towing.

Electronic brake force distribution (EBD) actively manages the brake force between the front and rear wheels, helping reduce braking distances and maximizing rear-wheel braking while towing. EBD uses data measured by sensors to compare wheel speed more than 100 times during each rotation. If wheel lockup is imminent, the EBD controller is able to redirect brake force within milliseconds to optimize available traction.

The front suspension is designed to counteract any tendency for the front wheels to toe-out during any brake-induced body dive - the tendency for the nose of the vehicle to be forced downward during hard braking. Ford engineers have designed in a small amount of toe-in under braking to counteract most of the natural toe-out motion, resulting in minimal geometry change during braking and thus help achieve very predictable stops.

F-150's new front suspension design places the brake deeper inside the wheel, which reduces scrub radius - the distance between the tire patch center and the steering pivot. Reducing the scrub radius reduces leverage on the steering pivot applied by road forces, further increasing stability and steering control while braking. The new F-150 has a dramatically decreased scrub radius - 15 millimeters vs. 50 millimeters in the 2002 F-150.

TOWING PERFORMANCE

The new F-150's chassis and powertrain make pulling a trailer easier than ever.

Its laterally stiff new rear suspension helps to resist side loads. The outboard rear shocks help reduce overall axle motion, while the 20-percent wider leaf springs limit side-to-side motion.

Precise steering and a stiff frame and body contribute to confident, stress-free trailering, while powerful brakes, beefed up for greater resistance to fade and enhanced by standard anti-lock control and electronic brake force distribution, maximize stopping power.

The 5.4-liter, 3-valve Triton ™ V-8 is expected to have competitive low-end torque, and the sophisticated electronic throttle control is designed to provide seamless, instant response and consistent transmission shift quality at various altitudes and vehicle loading. Four axle ratios - from 3.31:1 to 4.10:1 - are available, and all but the 3:31:1 can have optional limited-slip capability for enhanced traction.

HIGH-TECH ELECTRONICS IMPROVE OFF-ROAD DRIVING

While the most dramatic improvement in the F-150's drive experience comes on-road, Ford has steadily improved off-pavement performance with key upgrades. Four-wheel-drive models use the proven manual- or electronic shift-on-the-fly transfer case of the current F-150, and a selection of limited-slip rear axles is optional.

The standard electronic throttle control allowed engineers to incorporate a dedicated low-range accelerator response strategy for better control of torque in the most slippery conditions and reduced bucking while crossing rough terrain.

Aside from the new F-150, this type of system is available only on the new Range Rover and a $50,000 dedicated off-roader.

Braking performance off-road was the subject of careful tuning. On loose surfaces like gravel, anti-lock brakes can sometimes result in less swift stops than with conventional brakes, although the ability to steer while braking with ABS is thought to outweigh the sometimes longer stopping distances. F-150 braking engineers were able to improve off-road stopping distances by approximately 13 percent on the new pickup.

On rough roads, the stiff frame, compliant suspension and outboard rear shocks give excellent control, helping to reduce or eliminate the shaking, skating and axle hop certain surfaces can induce.

For the most serious off-road enthusiasts, the F-150 FX4 provides skid plates, heavy-duty shock absorbers, optional LT tires and a standard limited-slip 3.73:1 rear axle.

LARGER WHEELS AND TIRES

Even base series versions of the new F-150 are equipped with large 17-inch wheels, while Lariat versions have 18-inch wheels as standard equipment. Available tires range in size from P235/70R17 to LT275/65R18.

COMFORTABLE, CONTROLLED RIDE

The new F-150 combines a comfortable, isolated and well-supported ride with balanced communication between the vehicle and the driver. The new F-150's superior frame stiffness, advanced body mounts and carefully tuned suspension work together to deliver a quieter, more comfortable ride.

From an engineering perspective, any piece of structural metal acts as a spring. The only variable is its stiffness - how far it will deflect for a given load. By designing stiffness into the F-150's frame, engineers are able to use other, purpose-built springs to handle specific tasks, such as smoothing out the effects of road surface irregularities and isolating the passenger compartment from noise and vibration.

For example, all of the suspension mounting points on the frame are robust and rigid "large-footprint" designs to provide a strong base for the suspension system. Likewise, the engine mounting location is reinforced so that the hydraulic engine mounts can do their job of absorbing powertrain vibrations before they can get to the passenger compartment.

The bushings that attach the front suspension are soft in response to road impacts but stiff in response to cornering loads. Voids in key areas of the bushings let the rubber "give" under pressure and allow the front wheels to momentarily move rearward in response to a sharp jolt, resulting in a plusher ride.

Their direction-specific response gives them considerable stiffness against cornering loads, however, so the ride comfort they provide does not compromise steering response.

The front suspension's lower control arms are made of cast aluminum - a pickup truck first - to reduce "unsprung mass," the parts of the vehicle that move up and down as the suspension compresses and extends. The heavier a suspension component, the more likely it is to resist motion initially in response to a change in the road surface - and the longer it tends to remain in motion after the irregularity has passed.

SHEAR-STYLE BODY MOUNTS

Body mounts were also the subject of careful engineering innovation. These mounts serve to isolate the passenger compartment from vibrations that reach the frame. The mounts on both sides of the passenger cabin are built with a "shear" design. The basic concept is that of two concentric tubes, one bolted to the frame, the other bolted to the body structure. Rubber is bonded between the two tubes. As with the front suspension's control arm bushings, this design gives direction-specific response and protects the bushing material from the elements.

The metal tubes in the shear-style mounts also serve a crucial function in improving crash performance by limiting fore and aft movement of the passenger compartment.

Body and engine mounts were computer designed, but then subjected to repeated evaluation to make sure they achieved the team's goal: a quieter cabin and a more comfortable ride.

Computer tools include three-dimensional representations of the frame, powertrain, suspension and body, which can be run through deflection simulations that exaggerate actual movements by a factor of 50, to reveal areas that may need attention.

STIFF BODY STRUCTURE

The new F-150's body structure is approximately 75 percent stiffer than that of the current truck, which means that vibrations that are transmitted to the cab are less likely to induce after-shake, squeaks or rattles. Particularly impressive is that the gains in cab stiffness were made in conjunction with lengthening both Regular Cab and SuperCab models by 6 inches, and adding standard dual rear access panels on Regular Cabs.

A key contributor to the new F-150's stiff body structure is a special structural adhesive used to join the stampings that comprise the body's floor. Applied by robots for consistency and speed, the adhesive bonds the metal in the spaces between spot welds, forming a continuous seam. This provides increased stiffness, and reduces the localized stresses at the spot welds, for durability.

Many of the body stiffness improvements that promote a quiet cabin came from the aggressive efforts to provide integrity of the body shell during crashes. High-strength-steel reinforcements - particularly at the rocker panels - and stiff door openings are chief among these improvements.

REFINED POWER

The new 5.4-liter Triton TM V-8 engine that powers Ford's next-generation F-150 is designed with three valves per cylinder, variable cam timing and a host of other features that provide increased power - especially at low engine speeds - along with improved refinement and fuel economy.

The net result is an engine that delivers 300 horsepower at 5,000 rpm, and 365 foot-pounds of torque at 3,750 rpm - the new 5.4-liter, 3-valve Triton TM V-8.

The all-new, aluminum cylinder head - with two intake valves and one exhaust valve per cylinder for 24 valves in total - and a new cast-iron block balance this impressive power with better fuel efficiency and quieter operation.

This new technology builds on Ford's proven modular V-8 engine platform, while taking advantage of the capabilities offered by modern electronic controls. It is important to note that it isn't a single technology, but rather a suite of enhancements, that deliver these consumer benefits.

The new 3-valve engine will be Ford's first modular V-8 to use variable cam timing, which allows engineers to optimize intake and exhaust valve actuation across the engine speed range. It is the industry's first mass application of dual-equal variable-cam timing, which shifts the intake and exhaust valve timing together.

In combination with precise control of spark timing, fuel injection and the use of electrically controlled Charge Motion Control Valves in the intake ports, this technology produces impressive power and torque, particularly at the lower engine speeds that are so important to applications such as towing and heavy hauling.

NEW 5.4-LITER, 3-VALVE ENGINE CRANKS OUT TORQUE

Low-end torque has been a hallmark of the Triton TM V-8 engine line since it was launched in 1997. The 5.4-liter, 3-valve Triton TM V-8 will have even more of a good thing.

Torque is the twisting force that turns the wheels. It's what gets a heavily loaded vehicle moving from a standing start without straining, and keeps it accelerating as engine speed increases. The new 5.4-liter, 3-valve Triton TM V-8 has even more low-end torque than before, and considerably more torque at the high-end, thanks to its free-breathing, 3-valve head design.

"We make more than 80 percent of peak torque starting at 1,000 rpm," says Pete Dowding, Modular Engines Manager. "And the torque increases at a relatively steady rate throughout the rev band."

THREE-VALVE CYLINDER HEAD IMPROVES MAXIMUM POWER

The modular V-8 engine family is one of the most important product ranges in Ford's powertrain lineup. The company built 1.3 million of these engines in the 2001 calendar year.

While the two-valve modular V-8 line continues to deliver solid, efficient performance, Ford Motor Company's premium V-8 engines - such as the Mustang Mach I and SVT Cobra, Mercury Marauder and Lincoln Aviator powerplants - have shown the performance potential of multi-valve arrangements.

The use of two intake valves enhances fuel-air mixing prior to combustion. This helps to squeeze all the energy out of each combustion event, improving power delivery and fuel efficiency.

Multiple valves also enhance the engine's ability to "breathe" - that is, to move large volumes of air in and out of the cylinders - which is a key element of generating power. Four-valve engines remain Ford Motor Company's first choice for high-performance applications, where horsepower and acceleration are prime concerns, but they require considerable complexity, including two camshafts per cylinder head, which adds weight, cost and additional moving parts.

Ford engineers discovered they were able to get many of the benefits of a four-valve design - such as a central spark plug and symmetrical combustion chamber - using two intake valves and a single exhaust valve - with reduced weight and complexity compared with four-valve designs.

The two intake valves allow peak airflow of approximately 350 cubic feet per minute, compared with about 250 cubic feet per minute in the 5.4-liter Triton TM V-8, which uses a single intake valve per cylinder. This is a 40-percent improvement.

As an example of the engine team's holistic approach, this improvement in peak flow also is due to a completely redesigned intake port, which provides a much straighter path to the cylinder - very similar to the approach taken in racing engines.

With all-aluminum heads, single overhead camshafts, magnesium camshaft covers and a clean-sheet design approach, Ford's engineers were able to develop a three-valve-per-cylinder engine that has virtually no weight penalty over the two-valve V-8 engines. The three-valve head is actually dimensionally smaller than the two-valve design for the 5.4-liter engine, while offering more rigidity and strength. It also is easier to manufacture, with simpler drilling angles and straight-machined surfaces.

VARIABLE CAMSHAFT TIMING (VCT) OFFERS MULTIPLE BENEFITS

Ford's new three-valve cylinder head uses a single overhead camshaft for each bank of cylinders. The cam lobes press down on rocker arms to open the intake and exhaust valves, which are closed by coil springs, as in all Ford's V-8 engines.

Conventional camshafts are permanently synchronized with the engine's crankshaft so that they operate the valves at a specific point in each combustion cycle. In Ford's modular two-valve 5.4-liter V-8 engine, the intake valve opens slightly before the piston reaches the top of the cylinder and closes about 60 degrees after the piston reaches the bottom of the stroke on every cycle.

Variable camshaft timing allows the valves to be operated at different points in the combustion cycle, to provide performance that is precisely tailored to the engine's specific speed and load at that instant.

The Powertrain Control Module (PCM) directs solenoids to alter the oil flow in the hydraulic cam timing mechanism, which rotates the camshafts in relation to their drive sprockets. The unit can shift between fully advanced and fully retarded in milliseconds.

The result is enhanced efficiency under low-load conditions, such as at idle or highway cruising, and increased power for brisk acceleration or times of high demand.

"When you're driving, you can't tell that the cams are changing," says Dowding. "But you can certainly tell that there's more power when you ask for it."

The ability to control valve timing, as well as spark timing, allowed Ford engineers to design a combustion chamber with a higher compression level than in the two-valve V-8 engines - while still using regular gasoline octane levels. A higher compression ratio produces greater efficiency, delivering more power and improved combustion efficiency.

Among the other advantages generated by variable camshaft timing and electronic spark control:

A special "cold-start" strategy allows the new three-valve engine to bring the exhaust catalyst to operating temperatures more quickly, reducing emissions in the first minutes of operation.
Variable valve timing reduces pumping losses, the work required to pull air in and push exhaust out of the cylinder.
This design automatically channels a portion of burned gases back into the cylinder, to improve efficiency and reduce emissions. In addition to eliminating the external exhaust gas recirculation (EGR) circuit, this design reduces temperatures inside the intake manifold. Cooler combustion reduces production of the pollutant NOx.
Engineers were able to shape a torque curve that is higher at low engine speeds, without sacrificing high-end power.

CHARGE MOTION CONTROL VALVES AID COMBUSTION

The air-fuel mixture entering an engine behaves differently at different engine speeds and loads. At low engine speeds and light loads, relatively little air is drawn into the cylinders in a given time period, so it moves relatively slowly through the intake runners and into the cylinders. At high engine speeds, the intake mixture speeds up, as a larger volume passes through the intake runners over the same time period.

At lower speeds and lighter loads, the new three-valve engine uses an electronically controlled metal flap at the end of each intake runner - eight in all. These Charge Motion Control Valves are specially shaped to speed up the intake charge and induce a tumble effect in the combustion cylinder. This causes the fuel to mix more thoroughly, and to burn quickly and efficiently.

The CMCVs are controlled by an electronic motor and open at a predetermined point as engine speed increases. At higher engine speeds, they do not affect the intake charge at all. This allows undisturbed maximum flow into the combustion chambers at wide-open throttle.

The CMCV control motor is sound-insulated, so its operation remains transparent to vehicle occupants.

REFINEMENT AND RESPONSE OF ELECTRONIC THROTTLE CONTROL

New on both the 5.4-liter and 4.6-liter engines is a segment-first electronic throttle control that uses the input from the accelerator pedal to actively modulate the torque at the drive wheels. It is a direct descendant of technology first used in fighter aircraft.

Replacing the mechanical throttle linkage is an accelerator position sensor in the cabin, an electronic control circuit and an actuator at the throttle valve on the engine. A software algorithm takes into account the current operating status of the engine and ambient conditions, then operates the throttle as needed to best deliver the output requested by the driver. This has a number of key advantages over conventional throttle linkages, including seamless and consistent engine response, improved fuel economy and enhanced integration of vehicle systems, such as the transmission, variable camshaft timing, vehicle speed control and idle speed control.

A primary advantage over mechanical systems is the ability to tune the throttle response in relation to vehicle speed. When starting from a stop, for example, the "tip-in" of the accelerator is progressive and predictable, so that the driver can pull away smoothly. While under way, the truck responds instantly and strongly to more pressure on the pedal.

Additionally, the throttle-control curves are tuned to remain consistent over a wide range of operating conditions, including temperature and altitude, which influence engine response and power. Although the density of the air still limits peak engine power because there is less oxygen available for combustion, part-throttle response does not degrade with high altitude or high temperatures. Similarly, the shift schedule is electronically managed for a consistent feel under all driving conditions.

For off-road travel, Ford engineers used the flexibility of ETC to give four-wheel-drive F-150s a special throttle calibration while in low range. Only available on the all-new F-150, the new Range Rover and a $50,000 off-road specialty vehicle, this feature is designed to help rock-crawlers modulate engine power better in certain situations.

Because the stiff metal cable between a traditional accelerator pedal and the engine is eliminated, so is a traditional pathway into the cabin for noise and vibration. Pedal feel is not as subject to degradation over time due to friction and wear.

ETC SAFETY FEATURES

The ETC system has numerous safety features, including redundant sensors and double return springs at the accelerator pedal, dual sensors at the throttle valve, a closed-throttle-default actuator, redundant microprocessors and self-diagnostic software. Multiple fail-safe mechanisms are provided by the software and hardware, and the system is fault-tolerant: if only a minor fault is detected, "limp-home" modes allow the truck to move under its own power. In the remote chance of failure, the powertrain control module is designed to shut off the fuel injectors, preventing engine runaway.

ATTENTION TO DETAIL

Like the improvements in overall engine performance, improvements in the new three-valve engine's refinement result from a host of design features, rather than a single breakthrough.

In an example that is typical of the holistic approach Ford engineers brought to this new engine design, the same intake and exhaust manifolds that produce better air flow and improved efficiency also have been designed to offer quieter operation.

Ford's noise, vibration and harshness (NVH) engineers used computer modeling to design vibration-resistant ribbing and reinforcement into the composite intake manifold.

Because the intake area is so important to customers' perceived sound levels - it is the closest engine component to the driver's ears - sound is further managed through use of sound-insulating materials and a three-part tuned mass absorber in the "valley" beneath the intake runners, and with a new sound-absorbing engine cover that wraps around the edges of sound absorbing blankets at the front and rear of the engine.

The intake manifold alone represents a host of refinements to previous models. For the first time, the manifold arrives at the assembly plant with the fuel rail, air cleaner, throttle body and PCV unit in place. This makes assembly much faster and reduces complexity. The main portion of the manifold is friction-welded together for durability. Even the air filter assembly is innovative, with a slide-out drawer offering customers quick access to the cleaner element for service.

The new engine's pistons have been shaped with noise reduction in mind. The pistons have longer side skirts than in the past, which helps to control piston movement and minimize piston slap.

The three-valve design itself helped to reduce operating noise, as the engineers were able to balance the forces generated by valve and spring movement against each other, and aim the resultant force vectors toward the engine's overall center of gravity. This reduces total engine vibration - which equates to reduced noise.

The smaller cylinder heads naturally have a smaller surface area, which helps to reduce radiated noise. Roller-finger camshaft followers used in the cylinder head are both more efficient and quieter than non-roller designs.

Also at the top of the engine, new magnesium cam covers offer the vibration-resistance of aluminum, at reduced weight. They are further isolated from vibration via rubber mounts.

Reinforcing ribs cast into the cam covers, as well as a reinforcing plate in the underside of the covers, were both computer designed to minimize audible vibrations.

NVH engineers took a different approach with the engine's front cover, which must bear the mechanical stresses of the accessory drive belt. In the new "controlled standoff" design, solid metal is used at the points where the cover bolts to the engine block, but a rubber gasket damps vibrations between mounting points. This refinement alone is responsible for a one-decibel reduction in overall sound levels.

Behind this cover, the camshaft drive chains are now controlled by a new tensioner, which is reshaped to control small side-to-side chain movements, and the sounds associated with them.

The engine block itself is stiffer than in the past, through addition of computer-designed reinforcements cast into the block sidewalls, and thicker metal along the gasket surfaces. This, in combination with a new style oil pan made of a sandwich of metal around a plastic core, helps to minimize sound transmission through the bottom of the engine.

These designs were all validated through extensive measurement in Ford's Advanced Engineering Center dynamometer cells - acoustic rooms where developmental engines are run while surrounded by sensitive microphones. Ford has eight such dyno cells in its Advanced Engineering Center.

CONFIDENT SOUND QUALITY

While precise control of overall noise is key to delivering a refined powerplant, silence isn't everything. Ford's approach to powertrain development includes engineering the right kinds of sounds into each vehicle.

For example, Ford vehicles must provide appropriate audible feedback, as well as brisk acceleration, when the driver steps hard on the gas pedal.

This sound of power - only present during brisk acceleration - is created by tailoring the engine's NVH package to allow the right amount of fourth-order resonance to reach the passenger compartment. This tonal quality represents the sound of V-8 engine performance, and is tuned through precise shaping of the intake and exhaust systems, as a part of the entire NVH program.

This isn't a one-size-fits-all approach, however. While the Ford F-150 has a distinctive "tough truck" sound under full throttle, it is different than the throaty sound of the Mustang, for example. The Ford Thunderbird has its own powertrain character, which is distinct from that of the Ford Outfitters sport utility lineup.

Each vehicle development team crafts its entire powertrain package to achieve the brand's desired characteristics.

On the new three-valve engine, the equal-length intake runners are optimized for both power delivery and sound quality. For example, the variable Charge Motion Control Valves at the end of each intake runner close down to create turbulent airflow at low engine speeds, for efficient burning. At higher engine speeds, they open completely, to allow full airflow and quiet operation.

The exhaust manifolds represent a complete departure from the flat, pancake-style cast iron manifolds of the past.

The exhaust runners are twice as tall - 60 millimeters versus 30 millimeters - which helps to improve flow, and are more circular in cross-section, which improves NVH. The runners also are more widely separated than in past designs. They are braced together with computer-designed webbing, which is curved for NVH efficiency.

The new exhaust manifold design is able to forgo the exhaust gas recirculation port, due to the cylinder head's unique design. This reduces turbulence, and balances pressures among the exhaust runners.

ENGINE PRODUCTION

The new three-valve cylinder head will be manufactured at the Windsor (Ontario) Engine Plant with the full engine assembled at the Essex (Ontario) Engine Plant, also in Windsor. The two plants - both past winners of the prestigious Shingo Award for Excellence in Manufacturing - combined to produce 1.1 million V-6, V-8 and V-10 engines in 2001.

IMPROVEMENTS TO 4.6-LITER V-8

The 4.6-liter Triton TM V-8 achieves 231 horsepower at 4,750 rpm and an impressive 293 foot-pounds of torque at 3,500 rpm. Ninety percent of this torque is available at 2,000 rpm for strong towing performance and solid acceleration while hauling heavy loads.

It features a deep-skirted cast-iron cylinder block, cross-bolted main bearing caps tied directly to the skirt, deep-mounted cylinder head bolts and three-layer steel head gaskets. The single-overhead-camshaft (SOHC) valvetrain has roller-finger followers for quietness and is maintenance-free.

The new electronic fuel injection system is a returnless design, so it has fewer components, generates less gasoline vapor, and slightly improves fuel efficiency. Injectors with reduced mechanical noise and a stainless-steel damper-less fuel rail produce less noise, while streamlined component design improves engine appearance.

ENHANCED AUTOMATIC TRANSMISSIONS

Matched to the new 5.4-liter V-8 is a new 4R75E automatic transmission, an evolution of the 4R70E used on the current F-150. Upgraded to handle the torque of the 5.4-liter engine, this transmission shares patented upgrades with the 4R70E, which backs the 4.6-liter V-8:

A redesigned torque converter improves launch performance and increases efficiency.
A turbine speed sensor improves transmission control, providing the basis for fully electronic shift scheduling to limit "hunting" and to fine-tune shift speed and feel.
Increased microprocessor speed improves responsiveness and precision of the control system.
"Smart" fully electronic shift scheduling knows what the torque will be in the next gear so it chooses the shift points based on the vehicle's projected performance in the next gear.
Coupled with the electronic throttle strategy, the transmission computes the output torque required to maintain the vehicle speed, and chooses the correct gear and converter state accordingly.
A sealed case and lifetime transmission fluid make the transmission maintenance free, while adaptive pressure control maintains consistent shift feel over time.

By predicting the performance of the truck in the next gear, the computer-controlled transmissions provide a more sophisticated solution to heavy demands than a simple shift delay switch, such as the one-size-fits-all "towing mode" some competitors use.

FOUR-WHEEL-DRIVE SYSTEMS

F-150 is offered in both 4x2 and 4x4 drive configurations. The 4x4 models have two-speed transfer cases with optional electric shift-on-the-fly capability, controlled from a dash-mounted rotary knob.

Whether manually or electronically shifted, F-150's proven part-time four-wheel-drive system provides the traction truck users need for heavy hauling and off-road crawling. In low range, the electronic throttle control changes to a special off-road calibration for more precise torque management in the worst conditions, such as a sandy hill climb or when pulling a heavy boat out of the water on a moss-slicked ramp. For even more traction, a limited-slip rear differential is available on all F-150 models.

FUEL ECONOMY AND ENVIRONMENTAL PROTECTION

While final certification is not yet complete, Ford expects the new F-150 to offer competitive fuel economy.

The new three-valve 5.4-liter V-8 in the 2004 F-150 meets the U.S. federal government's Tier 2, Bin 8 Emission Vehicle standard. The 4.6-liter V-8 meets Tier 2, Bin 10 Emission Vehicle standard.

Beginning in 1998, Ford pledged to engineer all of its sport utility vehicles and Windstar minivans with Low-Emission Vehicle (LEV) certification, five years before regulatory requirements. In 1999, Ford announced that it would do the same with its popular F-Series pickup trucks.

SERVICEABILITY

Owning an F-150 - or any Ford product - should be hassle-free, even when it comes to maintenance. All 2004 F-150s have a new lifetime automatic transmission fluid that never needs changing.

On the 5.4-liter engine, the air filter slides out in a special drawer for easy changing.

Both the 4.6-liter and 5.4-liter engines can go 100,000 miles before their first scheduled tune-up, under normal driving conditions and with regular fluid and filter changes.

NEW SHAPE OF TOUGH: BOLD NEW F-150 FEATURES REFINEMENT

The all-new 2004 Ford F-150 creates a bold first impression as it extends Ford's tradition as America's Tough Truck leader.

It creates an even bigger lasting impression when F-150's standard doors are opened to reveal an interior design with truck refinement, comfort and spaciousness.

The new F-150 combines uncompromised truck toughness and capability with interior design excellence never before seen in a pickup, a pairing that is designed to change America's expectations of what a full-size pickup can be.

Ford's all-new F-150 redefines America's truck.

It celebrates the essence of the “Built Ford Tough” tradition but also breaks truck design conventions. A unique mix of capability and comfort, toughness and refinement and rigidity and versatility, the forward-looking F-150 charts new ground for the full-size pickup as only a leader can.

As the full-size pickup sales leader for 26 years running as of January 2003, Ford has used its consumer insight into the evolving full-size pickup market to create this new truck. The 2004 F-150 extends traditional Ford truck strengths, adds new technologies and features and is expected to sharpen F-150's appeal to a broader-than-ever range of truck buyers.

Comprehensive three-cab, three-box, five-series lineup

The new F-150 features a comprehensive full-size pickup product range. Core to the new F-150's design architecture is the insight that customers require more of their pickups than ever. Ford offers the industry's widest variety of body and trim configurations.

Instead of a one- or two-sizes-fit-all strategy, Ford F-150 offers:

Three cab choices –
- Regular Cab, with a single row of occupant seating and a behind-seat stowage area up to 16 inches in width.
- SuperCab, a four-door extended cab version featuring a second row of seating accessed by rearward-swinging access doors.
- SuperCrew, a crew cab that features two rows of seating and four forward-swinging, full-size doors.
- Three box lengths – 8-foot, 61/2-foot, and 51/2-foot – and a choice of two different box styles, Styleside and Flareside. The F-150 SuperCab 51/2-foot box combination is a new offering and a full-size pickup truck exclusive.
- Five distinct series offerings – from the workhorse F-150 XL to the refined F-150 Lariat – that reflect how Ford has sharpened its series differentiation across the F-150 range to address the differing wants and needs of full-size pickup customers.

All-new sophisticated
Tough Truck exterior design

The all-new F-150 exterior is confident, powerful, fresh and refined. Drawing on design elements from the current F-150, the F-Series Super Duty lineup and the Mighty F-350 TONKA concept truck, its taut, boldly chiseled shape resonates with Ford Tough Truck tradition.

“Creating an all-new F-150 was about asserting the toughness and truck capability of the sales leader,” said Patrick Schiavone, design director, Ford Tough Trucks. “We definitely wanted to push the design to a new level, to move the excitement needle up a notch. The result is a shape symbolic of F-150's strength but with an underlying tone of sophistication that really gives this truck aspirational qualities.”

In keeping with the overall design philosophy at Ford today, the new F-150 presents a well-executed design that will continue to look good well into the future. While it expresses strength and style and the confident “Built Ford Tough” attitude through its chiseled lines and brawny stance, designers spent extra effort on fine details that combine to give the new truck sophistication not previously available in the segment.

“We worked to perfect the most subtle proportions,” explained Craig Metros, F-150 chief designer. “These are details that truck designers never considered before. Ultimately, it's that attention to detail that makes the difference between mere good looks and great design.”

On the grille and tailgate, for example, the proud Ford blue oval badge is large, measuring 9 inches across, but exactly proportioned, and the surface has a subtle crown that adds three-dimensional “punch.”

Designers widened the front and rear track by more than 1.5 inches and placed the wheels in straightforward circular wheel arches. These actions plus larger standard wheel and tire combinations contribute to F-150's self-assured, “planted” stance. New 17-inch steel wheels and tires are standard on the workhorse F-150 XL, while aluminum wheels and larger, 18-inch designs are offered on higher-specification models.

Inspired by the F-Series Super Duty, designers created a bold front-end treatment for the all-new F-150. It features a steepened, inverted trapezoid grille with its strong, uncomplicated insert. An “up and over” grille-surround cleanly incorporates the design with F-150's raised-dome aluminum hood. The design conveys strength and symbolizes the power of F-150's engine family, led by a new flagship, 300-horsepower 5.4-liter, 3-valve Triton™ V-8 engine.

The face of the new F-150 also features new quad-circle-styled headlamps designed in form-follows-function clusters. The headlamp units are large, with lighting elements clearly visible through their clear composite lenses.

F-150's new front-end design features a fascia treatment that extends between the fenders and under the grille. Devoid of gaps and fit inconsistencies, the fascia lends a look of refined sophistication and precision.

The front view is finished by a bold bumper – either chrome or body-color depending on series – with a dished center section to accommodate F-150's lower grille. The bumper features large integral foglamps in most two-wheel-drive models, or tow hooks in most four-wheel-drive models.

“The combination of the bumper and fascia is a design detail that helps give F-150 its higher level of sophistication,” Metros said. “With most trucks the bumper looks like a bolt-on afterthought, with a big gap between it and the bodywork. The new F-150's face is more refined.”

Tall-shouldered and proud, F-150's new profile includes a distinctive lower feature line – “waterline” in design terminology – that is common across the entire F-150 range.

The waterline extends the length of the vehicle, joining the tops of the front and rear bumpers to create a visual body separation around the entire vehicle. Ford designers used the waterline as the starting point in creating visual differentiation among F-150's five different series offerings, such as two-tone paint treatments, while maintaining design coherence across the range.

Furthering the new F-150's visual strength is its high beltline, which draws attention to its chiseled, powerful flanks and a roofline reminiscent of chopped-top custom street trucks.

A more vertical tumblehome (the inward bow of the side windows) helps to balance the visual weight of the lower body while allowing nearly flush side glass, a mark of refinement. The doors of the new F-150 adopt the Ford signature stepped-down beltline of its larger Super Duty brother – a feature that aids outward visibility while providing an athletic rake that dynamically links the front and rear of the truck.

The F-150's cab profile varies according to model, but the variants share an underlying architecture designed for flexible, efficient manufacture. Fully inset front door designs – for a clean, aerodynamic look – are common for all cab variants.

Regular Cab models feature rearward-swinging access doors, giving the customer better accessibility to the space behind the seat. The behind-seat load space is 13 inches wide, large enough for golf clubs, toolboxes or five-gallon paint buckets. Each access door features an integral window that contributes to the new F-150's airy, spacious interior feel.

SuperCab occupants can enjoy F-150's anticipated-to-be first-in-class rear door power windows. Rear-seat passengers also benefit from the cab's six additional inches of length and a cleverly designed door handle that works from both outside the vehicle and inside.

On both rearward-swinging door designs neither exterior handles nor hinges are visible.

Two running-board designs – bench-shaped or tubular – are available. Their designs complement the new F-150 exterior.

At the business end of the new F-150, customers can specify the pickup box according to load length and box style.

The clean look of the F-150 Styleside box is available in all three box lengths – 8-foot, 61/2-foot and 51/2-foot. Its design incorporates steel inner panels and bolt-on outers of high-strength steel with precise, chiseled wheel arches. The Styleside features a body color tailgate design badged with a centered 9-inch Ford blue oval badge and the F-150 series badge on the left side.

F-150's new 61/2-foot Flareside box – available on STX, XLT and FX4 models – is formed of inner steel panels and exterior panels crafted of sheet-molded composite. The Flareside box design harks back to historic models with deeper, fender-like wheel flares and a different tailgate design that flares outward sportily at its upper edge for a “spoiler effect.” Black footpads and outer cargo hooks add further visual appeal and functionality.

Tailgates for both box designs incorporate Ford's new Tailgate Assist, an innovative and expected-to-be segment-exclusive feature to make opening and closing the tailgate easier. A torsion bar built inside the tailgate twists as the tailgate is lowered, bearing some of the tailgate's weight. As a result, the new F-150's steel tailgate feels more like a lightweight aluminum panel, but with no sacrifice in Tough Truck strength.

Interior design

On the inside, the new F-150 design is customized for the different series offerings. The 2004 F-150 demonstrates that toughness and craftsmanship go together like a finely crafted tool, reflecting the attention to detail Ford has devoted to occupant comfort, reduced interior noise and higher feature content. Although the new F-150 interior evokes an initial “wow factor,” designers have given it the substance to satisfy over the long run.

“The look is very modern, precise and industrial,” said Jim Smithbauer, F-150 design manager. “We designed the new F-150 interior with the knowledge that truck owners are spending more time than ever in their vehicles, both for work and personal use. Our objective for the new F-150 was to give them even higher levels of comfort, craftsmanship, versatility and convenience.”

Designers adopted a modular approach to creating F-150's instrument panel architecture, which accentuates the new interior design. The visual effect is created by bold vertical bands – or stripes – that give the design team tremendous flexibility to adapt different colors, textures and materials to customize the instrument panel across the F-150's five series offerings.

The results are an attractive two-tone instrument panel even on base models and stunning visual effects on higher series models. F-150 FX4 features “warm steel” effect bands while being distinguished by “carbon mesh” surface treatments for the instrument panel center stack and door panel inserts. Woodgrain effects are used for Lariat.

Designers also had flexibility to create three different instrument cluster designs. The FX4's cluster evokes images of classic aviation, and the high-specification Lariat features chrome-ringed gauges that match other chrome interior elements, including door handles. The cluster nestles under a subtle “eyebrow” in the upper instrument panel fascia.

The instrument panel houses functional round air registers – trimmed in chrome on higher-specification models – that are dimpled for fingertip-controlled opening and closing. In the off position, the vents are fully closed, enhancing the clean look of precision of the instrument panel.

The all-new F-150 introduces a flow-through center console option to the interior, which is matched with two captain's seats and a floor shifter for FX4 and Lariat models. The floor shifter, another expected-to-be segment-first, is a sophisticated design detail itself, finished in warm steel and chrome with a matching chrome gear indicator bezel.

The center console also incorporates an armrest, a stowage bin and cupholders. It integrates visually with the center stack of the new instrument panel and includes the audio and heating/ventilation/air conditioning controls.

Vehicles equipped with F-150's 40/20/40 split front bench seats are configured with a different instrument panel center stack that is optimized for middle passenger legroom.

Expected first-in-class overhead rail storage system

The new F-150 marks the debut of an industry-first modular overhead rail system that allows owners to customize interior storage options. It is standard equipment on XLT, FX4 and Lariat SuperCab and SuperCrew models.

At the heart of the overhead rail system is a pair of brushed aluminum rails integrated into the headliner and extending from just behind the rearview mirror to just behind the second row of seats. Capping the rails at the forward end is a dome light console and a large storage bin module.

The overhead rail system – with integral power supply – will allow owners to easily snap in additional modules, such as first aid kits, tool kits, flashlights and two-way radio holders as they become available. In addition to modules Ford develops for the overhead storage system, designers believe this system also could inspire innovation from the aftermarket to give F-150 owners even more choice.

An option on XLT, FX4 and Lariat SuperCrew F-150s is a rear-seat DVD entertainment system that attaches to the rearward end of the overhead rails. A high-performance 7-inch flip-down LCD screen, rear seat audio controls, handheld remote control and DVD player are included. Video and audio jacks enable rear passengers to connect gaming systems and other equipment.

Attention to design
detail and comfort

Ford designers' attention to detail is evident throughout the interior:

F-150's doors are trimmed with slightly concave-shaped interior panels that maximize passenger room. The door panels feature large padded armrests designed to suit a wide range of statures. The doors also feature a large map pocket with a molded-in holder for a 20-ounce bottle.
Grab handles on the A-pillars are cleverly integrated into the pillar cladding, and feature a soft-touch grab surface. Points of contact like these provide the customer with the most lasting impressions about a vehicle's “feel” and quality.
F-150 XL and F-150 STX models feature hose-out floors that their owners consider essential. Instead of a generic grained rubber effect pattern for hose-out floors, Ford designers created a metal “diamond plate” effect in the rubber floor surface.
Interior surfaces on the F-150 Lariat are distinctively stitched, including the center console and the eyebrow-shaped binnacle, a detail normally found on exclusive luxury cars, not trucks.
Pill-shaped surface details punctuate the interior, adding dimension and visual appeal.

Comfortable Seating

A 40/20/40 split bench front seat is standard equipment on all new F-150s, even the base XL. XLT versions can be specified with front captain's chairs and a center storage console, and the FX4 and Lariat SuperCab and SuperCrew are available with optional front captain's chairs that include a full-size pickup first flow-through console and floor shifter.

All SuperCab and SuperCrew versions have a 60/40 split rear bench seat that easily flips up to make room for cargo. The SuperCab now features a new backrest recline of 21 degrees to match the more natural seating position of the SuperCrew.

Lariat models have power adjustment of the driver's seat as standard equipment, and can be equipped with heated seats for the driver and front passenger. A power-adjustable driver's seat is optional on XLT and FX4 SuperCabs and SuperCrews, and Lariats have an optional memory feature that allows two drivers to pre-set the adjustment of the seat and the power-adjustable pedals.

The differentiated new F-150 series family

Five distinctly individual models have been created for the new F-150 as Ford has worked to hone the character of the truck for key customer segments within the vast full-size pickup market. The objective for designers was to create a family of F-150 series offerings, each with a distinctive personality.

From the base model to the top of the range, each series gains new comfort and convenience features – some of them expected to be firsts for the full-size segment.

F-150 XL – The workhorse of the line-up, the F-150 XL is the truck that gets the job done, a truck proud to retain the hose-out floor symbolic of the pickup's role in helping to build America. Larger 17-inch steel wheels are standard, and the XL has a bold, forthright grille design and a lockable tailgate. Interiors can be specified in either vinyl or cloth.

F-150 STX – Ford has created the F-150 STX for the value-oriented owner who needs work truck capabilities for hauling and towing but wants a sporty, stylish look. STX models are available in Regular Cab or SuperCab with body-color grille surround and bumpers, and 17-inch sporty cast aluminum wheels.

F-150 XLT – The F-150 XLT is the Tough Truck designed to carry people and cargo alike. XLT is geared toward a wide array of jobs such as hauling, towing and recreation. It features a unique, optional silver two-tone paint finish, unique grille treatment and its own 17-inch cast aluminum wheels as standard equipment. Inside, premium cloth is featured on either the 40/20/40 split bench seat or optional dual captain's chairs. Chrome accents make the new instrument panel design even more distinctive.

F-150 FX4 – For serious 4x4 truckers, the new FX4 is aimed at outdoor enthusiasts for whom a truck with four-wheel-drive capability is a critical lifestyle element. The new F-150 FX4 has the capability and the image they're seeking -- a bold, individual statement. New optional 18-inch machined aluminum wheels complement body color bumpers, a distinctive grille and optional Dark Shadow Grey lower two-tone treatment add to the FX4's purposeful look. Inside the FX4 is just as individual, with unique “warm steel” accents on the instrument panel, center console, doors and steering wheel. Its aircraft-inspired instrument cluster, carbon-mesh accents and chrome-ringed air registers are further design touches. Optional captain's chairs can be specified in either sporty cloth or sporty leather.

F-150 LARIAT – The top-of-the-line F-150 Lariat is a unique combination of toughness and refinement, geared to buyers who view their trucks as a reward for achievement. Many Lariat owners depend on their trucks for towing, such as boating enthusiasts and horse owners, but want comfort, refinement and convenience features along the way. Lariat features optional premium captain's chairs with the flow-through console or a standard 40/20/40 leather split bench seat. The instrument panel and center console contain finely crafted stitched surfaces in Medium Pebble or Ebony, augmented by woodgrain touches on the doors and instrument panel center stack. Lariat's instrument cluster also is unique to the series, with cream-colored gauges ringed in chrome to complement the chrome-ringed air registers and chrome door handles. The steering wheel has built-in controls for key audio and climate control functions. The theme of American luxury continues on the exterior of the new F-150 Lariat, with an optional Arizona Beige lower two-tone paint treatment, chrome bumpers and a unique grille, along with 18-inch bright aluminum wheels.

SAFETY AND SECURITY - AN F-150 STRENGTH

The all-new Ford F-150 has been engineered with an uncompromising focus on safety. Across the line-up, the new full-size pickup from the Tough Truck leader has the strength, technology and know-how to protect its occupants.

The same ruggedness and durability that make this the hardest-working F-150 ever also provide a strong layer of protection - from the hydroformed and fully boxed steel frame to the stiffer new passenger compartment design. But the safety story goes beyond strength - F-150 brings sophisticated technology to the job of protecting its occupants from harm.

CRASH-OPTIMIZED STRUCTURE

If a collision is unavoidable, the new F-150 helps to protect its occupants with a structure designed to help absorb and dissipate crash energy before it can reach the reinforced passenger compartment.

The U.S. Federal Government's New Car Assessment Program (NCAP), which issues star ratings, simulates a full-width frontal impact at 35 mph and is largely a test of the performance of the restraints system. Ford expects the new F-150, which incorporates the proven Ford Personal Safety System, to continue to perform well in this test.

In the structure-demanding Insurance Institute for Highway Safety's offset frontal crash test, Ford expects the new F-150 to earn high marks, based on internal measurements. It also will be Ford's first vehicle to meet the stringent new Federal Motor Vehicle Safety Standard (FMVSS) 208 - an updated series of federal requirements that now includes air bag and offset crash performance.

This standard governs protection of occupants with and without safety belts, from very small (5th percentile) to average-sized adults. It includes full frontal and offset crash testing, as well as crashes at a 30-degree angle.

In offset frontal crashes, the impact is borne by only one side of the front structure, placing a premium on the performance of energy-absorbing structures, such as the bumper beam and frame rails. The new F-150's strong hydroformed front frame rails are built with computer-designed front horns to help manage crash forces. In an impact, these areas of the frame are designed to collapse in an accordion fashion, dissipating energy before it reaches the passenger compartment.

Safety engineers for the new F-150 stamped a wave pattern into the front horns, tailoring the shape and wall thickness to create trigger points where the frame sections would begin to collapse under impact energy.

Innovative design added additional space to this crush zone. The front frame rails extend through cutouts in the fully boxed bumper beam to its front face, where they are welded in place. In the millisecond-world of crash impacts, this extra crush space represents a worthwhile gain.

The front crush structure is built from C-channel steel sections welded together to form fully boxed frame rails. These sections meet the robust hydroformed frame at a point well forward of the passenger compar TM ent, providing a rugged steel platform beneath the cabin. Special reinforcements on the frame rails further improve the frame stiffness there.

The frame design works with new shear-style body mounts that use two concentric tubes of steel around the rubber body mount to keep the passenger compartment from shifting front-to-rear in an impact.

Combined with exceptionally stiff door sills and door openings, the hydroformed frame is able to help keep the main section of the frame from twisting during an offset crash. With a stiff frame, the front wheel on the side of impact engages a stout "torque box" just forward of the lower front door hinge, channeling impact energy along the rocker panel, which is made of high-strength steel. This helps maintain the integrity of the foot well.

The new F-150 provides exceptional side impact protection through use of steel door beams, sturdy door sills and a strong body structure.

RESTRAINT SYSTEMS

An energy-absorbing frame and solid passenger compartment represent just half of Ford's occupant protection strategy. Advanced restraints complete the portfolio of safety features on F-150, which now includes occupant classification as part of more than a dozen elements that make up the Personal Safety System TM .

With it, frontal air bags offer multiple deployment levels to tailor inflation force to the severity of the crash, safety belt use and other factors.

If the driver's seat is positioned toward the front, as in the case of shorter-stature adults, the driver's air bag deploys at lower force - or not at all - depending on crash severity.

Safety belt usage is taken into account - for example, an unbelted driver may receive air bag deployment at a lower crash severity level. A driver who is wearing a safety belt in a lower-severity crash may not need an air bag at all, and it would be suppressed.

For the all-new F-150, safety engineers added passenger-weight-sensing technology to tailor deployment of the front outboard passenger air bag, as well.

If the passenger-seat sensor detects no weight on the seat - or very little weight, such as a newspaper, a half-dozen bagels or work gloves - the passenger air bag is automatically switched off. The passenger air bag also can be turned off manually in Regular Cab models using a key-activated switch.

If more weight is on the seat, as with a small child, the air bag remains turned off and a light on the instrument panel alerts the driver with the message "PASSENGER AIR BAG OFF." If an adult is seated properly in the passenger seat, the air bag is automatically switched on, ready to inflate within milliseconds if needed.

The passenger side air bag can deploy at any of three levels, as commanded by the restraints control module computer. As with the driver position, front passenger safety belt usage is taken into account when tailoring air bag deployment.

A vehicle occupant's best line of defense in crashes remains the safety belt.

The new F-150 has three-point belts at all outboard seating positions, and uses a three-point belt in the center rear seating position of SuperCab and SuperCrew models.

Further helping to reduce peak forces, load-limiting retractors pay out shoulder belt material as appropriate to help ease occupants to a stop. These retractors contain metal torsion bars that twist under crash forces - like a wrung-out washcloth - to release energy slowly, in relation to the millisecond-speed of typical crash events.

The 2004 F-150 has standard adjustable head restraints at all outboard seating positions.

BELTMINDER ™

A complement to the Personal Safety System is Beltminder TM . Ford Motor Company's Beltminder TM technology reminds the driver and front-seat passenger in the F-150 to buckle up by sounding a gentle tone and displaying an icon on the instrument panel. This is the first truck to offer the Beltminder ™ safety belt reminder system on the passenger side.

This reminder continues intermittently for up to five minutes. A recent study found that virtually all Ford truck owners consider this to be an effective, welcome safety reminder. The system is particularly valuable in pickup trucks, since they are frequently used for short trips where drivers might not think to buckle up.

Ford's Beltminder TM system has increased safety belt use by 5 percentage points in Ford vehicles equipped with this technology, according to the Insurance Institute for Highway Safety, which defines the result as "significant." Every percentage point improvement in nationwide safety belt usage can save an estimated 300 lives per year, according to U.S. government estimates. The U.S. National Highway Traffic Safety Administration has urged other manufacturers to follow Ford's lead in implementing this important safety feature.

INSTALLING A CHILD SAFETY SEAT

All new F-150 pickups have standard provisions for safely securing a LATCH-compatible child safety seat. There are three sets of LATCH (Lower Anchors and Tethers for Children) fixtures and top tether anchors across the rear seat of SuperCab and SuperCrew models, and a top tether anchor on the front passenger seat. Regular Cab models have both LATCH lower anchors and a top tether anchor on the front passenger seat.

The LATCH system is designed to make installation of child car seats easier and more secure while reducing the variability often associated with different vehicle safety belt/child safety seat designs and components. It incorporates universal rigid, metal anchoring points in the vehicle seat bight (where the seat back and cushion meet), providing a secure and easy installation of a LATCH-compatible child safety seat.

ACCIDENT AVOIDANCE

With the precision of its all-new rack-and-pinion steering system, the stability of its revised rear suspension, its wide stance and powerful anti-lock disc brakes with electronic brake force distribution, the new Ford F-150 provides the first measure of defense in emergencies: controllability.

The F-150's brakes have been improved for 2003, with larger, thicker rotors front and rear, and 60-percent stiffer calipers that improve response and braking feel. Electronic anti-lock braking (ABS) compares wheel speed and adjusts braking pressure as needed to prevent lockup and reduce stopping distances in most panic-stop situations.

Electronic brake force distribution uses data from the ABS, measuring wheel speed 100 times in every rotation, to balance braking force front-to-rear. On a truck, this is especially effective, because it allows more braking force to be channeled to the rear wheels when the truck is carrying a load. This can dramatically reduce stopping distances when towing, as well.

Likewise, the new F-150's commanding seating position, large mirrors and drop-glass beltline provide the visibility to help avert accidents. Sound ergonomics, including a standard tilt steering wheel and available power-adjustable pedals, help to tailor the driver's environment.

SECURITY AND CONVENIENCE FEATURES

With 6 more inches of cab length on Regular Cab and SuperCab models, the F-150 provides more lockable cargo volume than ever before - up to 13 inches behind the front seat of Regular Cab models.

Numerous features protect customers, the new F-150 and its contents from theft, lockouts, fender-benders and more:

Ford's patented SecuriLock ™ passive anti-theft system protects against drive away theft through the use of an electronically coded ignition key that communicates with the engine management computer. The vehicle starts and operates only when the electronic code in the ignition key matches a code programmed in the vehicle, thwarting attempts to hot-wire the ignition. The system arms automatically when the ignition is switched off and has 72 quadrillion possible codes.
Available keypad entry is a pickup truck exclusive and adds to the convenience of remote keyless entry.
The spare wheel has a standard keyed lock to prevent theft.
A lockable tailgate is standard on all models.
On vehicles equipped with power locks, doors lock automatically when the vehicle begins moving.
A battery-saver feature automatically turns off courtesy lights if the vehicle is left unattended for a pre-set time.
An available sonar-based Reverse Sensing Aid sounds in-cabin audio warnings if an obstacle is detected while reversing.
Fully inset doors make prying into the passenger compartment more difficult.
Fuel tank capacities of up to 35 gallons provide a long range between fill-ups, allowing the convenience of fewer stops.

2004 FORD F-150 MEETS EXPANDING CONSUMER NEEDS

Power. Package. Presence. The Ford F-Series is America's truck. Led by the F-150, F-Series has defined the full-size pickup in the United States and for more than two decades has been the country's best-selling vehicle.

Ford pioneered the pickup with the Model T, gave it the first V-8 engine, created the famed Twin I-Beam suspension, and led the market by being the first in the under-8,500 class to introduce both an extended cab model with a standard third door, the SuperCab, and a crew cab model with four forward-swinging full-size doors, the SuperCrew. Along the way, Ford has amassed 85 years of experience in the truck market, built on 55 years of legendary F-Series accomplishments and established a brand that is synonymous with tough truck leadership.

Today, with its strong heritage as a foundation, Ford is redefining America's truck. The new Ford F-150 introduces a Whole New Era of Built Ford Tough.

THE F-SERIES SALES LEADERSHIP STORY

The story of the Ford F-Series is one of sustained sales leadership. From the farm to the construction site, landscaping job or boat ramp, the full-size pickup has earned a special place in the fabric of American life, and F-Series is America's choice. F-Series continues to stand out through its legendary value, quality, time-tested durability and multitude of accomplishments in the motor sports world. F-Series outsells every other full-size truck brand. In fact, F-Series has been America's favorite vehicle - car, truck or SUV - for 21 years running, as of January 2003.

Statistics on the full-size pickup tell a compelling story of its significance on the American landscape and its importance to Ford Motor Company and other automakers. In 2001, full-size pickups comprised the best-selling single segment of the U.S. marketplace:

Full-size pickup trucks accounted for sales of nearly 2.3 million units.
Full-size pickups represented 13 percent of all U.S. vehicle sales. In major regional truck markets, led by Texas, full-size pickups were even more dominant, achieving 24 percent of all vehicle sales.
Three of the top-10-selling vehicles in the United States were full-size pickups.

Ford F-Series started the 1990s as the market leader and extended its lead despite increased competition.

"Ford has a long and storied history of truck leadership with F-Series," said Matt DeMars, executive director for tough trucks at Ford Motor Company. "We have a huge owner body and a reputation for toughness and durability that is unsurpassed in the industry. Our well-developed customer insight helps us anticipate the 'next big thing' in the market, and we continue to give new customers the most appealing products like SuperCrew, like the F-150 King Ranch, the F-150 Harley Davidson and the F-150 Lightning from SVT. Innovations like these have helped drive market growth."

During the 1990s, Ford conducted extensive market research to gain a better understanding of consumer wants and needs. The company polled more than 10,000 car and truck owners of various makes and models for valuable perspective on how vehicles fit into customers' lives.

Among the most significant insights was the dramatic evolution of the full-size pickup segment. It became clear that while truck customers continued to value traditional workhorse capability and functionality, they wanted a truck that would express their individuality. This would serve as a roadmap for developing the new F-150.

As the segment has expanded, models with more space, more versatility, more comfort and more features have grown in popularity. And the full-size pickup market has begun to appeal to a much broader range of customers while still retaining its traditional owner base. New four-door cabs meant more customers could migrate to the pickup for its versatility for people and cargo.

Ford was at the forefront of the growing personal-use trend, playing the leader's role in bringing more space to pickup customers. Ford introduced SuperCab and SuperCrew variants of the F-150 that brought true F-Series capability to a more diverse customer base and brought product flexibility and greater choice - without compromising Ford toughness. Extended cab models started the 1990s with less than 20 percent of the total market. Today, they represent approximately 80 percent of sales due to the increased functionality afforded by greater cargo and people space.

WHERE FORD F-150 HAS LED, THE MARKET HAS FOLLOWED

While the pickup market has broadened and diversified in 10 years, new customers and traditional truck buyers share one passion - a desire for uncompromised truck toughness and capability. Ford F-Series embodies this spirit, its toughness central to its enduring customer appeal.

In a decade of substantial market growth, Ford asserted its sales leadership convincingly. The year 2001 culminated in an all-time sales record for the Ford F-Series of 911,597 units. In truck terms, this performance was a rout. F-Series' nearest rival trailed by nearly 200,000 units.

With sustained popularity and a substantial leadership margin, Ford was readying its 'next big thing.' Behind the scenes, development of the all-new F-150 was well under way for a debut in January 2003 - when F-Series would mark its 26th consecutive year as America's truck sales leader.

The numbers tell the story of why Ford is aggressively striving to extend its leadership as the best-selling full-size pickup. The F-Series is extremely important to Ford's success. It accounts for nearly 28 percent of Ford Division's sales and 23 percent of Ford Motor Company's total U.S. sales.

"There's no question about the importance of trucks to the Blue Oval," said Doug Scott, Ford Division truck group marketing manager. "For Ford and our dealers, the F-Series is absolutely the foundation of the franchise."

STRATEGIC DIRECTION FOR A NEW F-150

Given the significance of F-Series to Ford's overall business, Ford adopted a strategy to build on the momentum of its sales leadership with the development of the all-new F-150. The objective: Redefine America's truck and launch a Whole New Era of Built Ford Tough. This applied across the entire development process, including design, engineering and manufacturing.

DESIGN AND DIFFERENTIATION

Ford's strategy was developed with the recognition that the market had evolved significantly since the most recent F-150 redesign was introduced in January 1996. Ford's understanding of this expanding and changing customer base was central to keeping F-150 at the forefront.

Customer insight shaped a two-part strategy that guided development of the new product:

Reinventing the Leader - With courage to set a new direction for the marketplace, F-150 needed to emphatically assert its leadership by extending its recognized strengths in every key area important to truck customers. The new F-150 must be a Tough Truck all-around, taking advantage of the momentum of its predecessor and leveraging Ford's reputation for truck toughness and capability. However, in the spirit of reinvention, it must also redefine the segment in terms of spaciousness, versatility, refinement and safety. In addition, development of the new F-150 also relied on Ford's unparalleled customer insight, which pointed to evolving customer needs in the areas of ride, handling and comfort.
Sharper Segmentation - While redefining America's truck, Ford seized the opportunity to strengthen its position with newly developing subsegments within the full-size pickup market. Within the rapidly expanding and diversifying market, the F-150 lineup must be developed in a way to create sharper distinctions within its range to address more directly differing customer wants. The strategy and execution must distance itself from a conventional "one size fits all" approach.

WHOLE NEW ERA OF BUILT FORD TOUGH

Just as an Olympic champion trains to shatter previous records, establishing a whole new era of Built Ford Tough meant improving the Ford F-150 where it matters most for customers, including customers migrating to full-size trucks. Making the 2004 Ford F-150 unapproachable for competitors in terms of all-around product strength was the objective.

A broad range of overarching product enhancements that would benefit every F-150 customer was the result:

Stronger stance and style - The new F-150 features an all-new design, with a bold exterior shape that exemplifies Ford truck toughness and capability. The interiors boldly take the full-size pickup into a new dimension of comfort and refinement.
Power - Ford's new 5.4-liter, 3-valve Triton ™ V-8 engine produces 300 peak horsepower - a 15-percent improvement over the previous award-winning 5.4-liter engine, and 365 foot-pounds of torque for improved low-speed and peak pulling power. Mated with the new 4R75E transmission for smoother shifts and improved fuel efficiency, the 5.4L 3V also contributes to a quieter cab environment for F-150 customers.
Even tougher - The fully boxed frame is approximately nine times stiffer torsionally than its tough predecessor, providing the foundation for enhancements in durability, safety, driving dynamics and refined, quiet ride.
Superior driving experience - Tremendous attention to detail has been applied to the chassis of the F-150 to deliver a confident, capable driving experience. F-150's newly designed rear suspension, featuring outboard shock, is among the details that contribute to more confident and precise handling both in everyday driving and while towing a trailer.
Increased interior spaciousness - Regular Cab and SuperCab models have a passenger compartment that is six inches longer, providing more space inside for occupants and their gear. For SuperCab models, that extra length means increased rear-seat comfort for three adults. For Regular Cab, it means 13 inches of secure storage space behind the seat.
Greater access - Reflecting consumer demand for ease of access for both people and cargo, Regular Cab models feature new, class-exclusive access doors that open up new stowage possibilities and accessibility behind the seat.
More cargo capacity - The new F-150's cargo box is 2 inches deeper, providing greater cargo volume. Plus, a new class-exclusive Tailgate Assist feature, which is standard across the lineup, helps owners of all statures open and close the gate.
Enhanced safety - Inherent strength and toughness plus the F-150 Personal Safety System's ™ new occupant sensing technology for the front outboard passenger makes the all-new F-150 a strong choice for safety. It has been engineered to exceed the rigorous new federal government safety standard, FMVSS 208, which governs air bag and off-set crash performance.

"Our goal was to create a full-size pickup that is stronger than ever and meets previously unaddressed customer needs," said Frank Davis, F-150 chief program engineer.

"We've created an all-new architecture that puts F-150 in a class of its own and demonstrates that pickup owners don't have to accept things like an uncomfortable ride and spartan interiors," Davis said. "We know our competitors will attempt to follow F-150's lead, but this all-new architecture will be difficult for them to copy."

SHARP DIFFERENTIATION FOR A DIVERSE MARKET

The 2004 Ford F-150 features five distinct series offerings. This segment differentiation strategy is at the heart of Ford's approach to appeal to the diversity of the full-size pickup market in America.

"The sharpening of our product differentiation represents one insight into today's full-size truck market and our latest thinking on how to appeal to its major subsegments," Scott said. "This has driven our approach to create a distinct character for each of the five series offerings of the all-new F-150."

F-150 traditionally has been well equipped to respond to diverse customer needs. With a wide array of choices in terms of cabs, box lengths, powertrains, towing options and equipment levels, this product can be configured to meet very specific functional needs.

The 2004 F-150 extends that tradition. Each model is distinct at a glance, with the power, package and presence that will appeal to a diverse customer base.

The F-150 series range features familiar names but with new, sharper identities. Ford has configured its lineup for strength at the center of the market, while appealing to traditional workhorse buyers and luxury customers at the edges and adding two more defined "image" segments in-between:

F-150 XL

The workhorse of the F-150 lineup, the XL delivers capability and functionality - traditional F-150 strengths. The XL target customer wants a truck predominantly for work with towing and hauling capability, but also enjoys a truck from a personal perspective. Many customers in this group are family-oriented truck enthusiasts who also enjoy outdoor pursuits, such as camping, hunting and fishing.

Available in Regular Cab and SuperCab bodies with a 61/2-foot or 8-foot Styleside box, a choice of two V-8 engines and either a 4x2 or 4x4 drivetrain, the XL benefits from additional interior space, all-four-door accessibility and standard 17-inch wheels. Regular Cab models introduce the XL to Ford's new rear access doors, which open up a more spacious area behind the 40/20/40 split bench seat for stowage.

Toolboxes, five-gallon paint buckets and even golf clubs can be secured inside the vehicle without impeding the three-across seating. Plus, it embodies toughness and durability thanks to F-150's rigid new fully boxed frame and the versatility of the new standard 40/20/40 cloth split bench seat. New features also include standard tilt steering wheel and a display center system in the instrument panel.

F-150 STX

A growing base of customers is aspiring to the full-size segment but looking for a sportier image to match their lifestyles. Customers in this group tend to be younger and value-oriented and believe a truck rather than a car best fits their active lifestyle and is best for their basic transportation, light hauling and towing needs. The new F-150 STX combines a sporty style with workhorse capability and value to fit a unique set of customer needs. Available as a 4x2 or 4x4 in Regular Cab or SuperCab with a standard 61/2-foot Styleside, 51/2-foot Styleside or 61/2-foot Flareside box, STX is powered by the 4.6-liter Triton ™ V-8 engine and equipped with unique 17-inch sporty cast aluminum wheels. It has a cloth interior with a 40/20/40 split bench seat and offers an available premium audio system with in-dash 6-CD player and subwoofer.

F-150 XLT

At the heart of the five-series lineup, XLT is expected to be the most-popular seller due to its capability, versatility, comfort and convenience. The XLT model is aimed at a predominantly family-oriented group of customers who need a truck capable of hauling or towing, when necessary, but also appreciate the versatility of the F-150 during personal or recreational pursuits. It is available in Regular Cab and SuperCab configurations, both benefiting from an extra six inches of body length, or as a SuperCrew model. XLT offers three choices of Styleside box (5 1/2-foot, 6 1/2-foot or 8-foot) or a 6 1/2-foot Flareside box. Of special note is the introduction of the class-exclusive new, more "garage-able" combination, the SuperCab with a 5 1/2-foot Styleside box. The XLT also offers two V-8 engine choices, 4x2 or 4x4 options and standard 17-inch wheels. Plus, XLT comes with an array of additional standard equipment, such as second-row power windows and a new overhead storage system on SuperCab and SuperCrew models. Power mirrors, Autolamp, delayed accessory power, outside temperature/compass display and speed control are among other standard XLT features. Optional equipment includes a defrosting rear window, foglamps on 4x2 models, a keyless entry door keypad and a power moonroof (on SuperCab and SuperCrew).

F-150 FX4

This series was conceived to meet the needs of full-size truck buyers who demand the off-road image and power of a four-wheel-drive pickup. Four-wheel-drive capability and style are central to the character of the FX4 model. It is aimed at a base of customers who enjoy the outdoors and off-roading. They're looking for an attention-getting truck with 4x4 excellence, that is just as capable of pleasure driving. F-150 FX4 customers have a broad array of choices, including a new-look 61/2-foot Flareside box or either the 51/2-foot or 61/2-foot Styleside box. All three cab styles also are available. A bold, distinctive exterior look, optional 18-inch machined cast aluminum wheels and unique sport cloth or sport leather interiors - with a choice of split bench seats or captain's chairs including a class-first flow-through console and floor shifter - make FX4 the ideal truck for an active lifestyle. The increased horsepower and torque of the F-150's new 5.4-liter, 3-valve Triton ™ V-8 engine will be especially important to buyers in this sub-segment.

F-150 LARIAT

Demand for a truly premium truck with traditional F-Series capability has led to the creation of an even more distinctive and comfortable F-150 Lariat. The target customers view their truck as a reward for achievement and desire a fully equipped vehicle. Traditional themes of American luxury resonate with this group of truck buyers, who use their vehicles for everyday driving in addition to road trips and towing boats, horse trailers or travel trailers. Optional Arizona Beige two-tone paint, unique 18-inch bright aluminum wheels and the most refined interior design in pickup history make the Lariat stand out from the crowd, whether configured as a SuperCab or SuperCrew. Leather interiors, featuring either optional captain's chairs with the segment-first floor shifter or in a versatile standard 40/20/40 split bench, make the Lariat ideal for carrying people in style, comfort and refinement without shying away from Tough Truck tasks. Other Lariat features include an in-dash messaging center, electronic automatic temperature control, optional DVD player and memory power-adjustable seats and pedals. Its large, functional, heated side mirrors have built-in repeater lamps synchronized with the turn signals.

SMART ENGINEERING ADVANCEMENTS

Smart engineering techniques have been central to development of the all-new 2004 Ford F-150. They have been a key driver of the affordable business structure allowing for such a wide range of offerings and combinations.

From the backbone of the truck - its rigid, fully boxed frame - to its sophisticated safety features, the new F-150 was developed with extensive use of Ford's computer-aided toolset called C3P. An integrated package of computer-aided design, computer-aided engineering, computer-aided manufacturing and a comprehensive product information database, Ford's C3P system allowed designers and engineers to create the new vehicle largely in a digital environment.

The strengths of C3P played a major role in enabling Ford engineers to develop a product range with a high degree of complexity. This allows F-150 customers maximum freedom to configure their trucks according to precise needs, ranging from cab type to box size to powertrain choice to drivetrain configuration.

"With a program of the scope of F-150, C3P provides massive smart-engineering efficiencies," said Bill Osborne, director of engineering for Ford Tough Trucks. "That's important because people buy trucks because they represent excellent value. Our engineering objective for the new F-150 has been to extend our reputation for toughness and capability while offering the kinds of upgrades and creature comforts that customers want and traditionally haven't been able to get."

The broad capabilities of C3P allowed Ford engineers to reduce the number of hard prototypes created during the engineering process to test new component designs. The sophisticated array of computer tools allowed engineers to build virtual prototypes of their digital designs and to "test" their function entirely in the digital environment. This cuts significant time from the development program, speeds the product to market and allows engineers to concentrate their efforts on perfecting functionality rather than testing a succession of prototype parts, as done in the past. Virtual prototyping has paid massive dividends for Ford, especially at the scale of a project like F-150.

Surgically adding value where it matters most to customers was another facet of Ford's smart engineering approach.

"When we developed the F-150 SuperCrew in 2000, the market embraced it enthusiastically and the industry followed," Davis said. "SuperCrew went on to play a major role in extending the appeal of the full-size pickup. As the leader, we had the customer insight to recognize the needs of the changing customer base and we added value to the F-150 accordingly. What we learned in the process is that customers want even more. The all-new F-150 is designed to give it to them."

F-150's finely crafted and distinctive new interior designs are a vivid example of adding value. They reflect Ford's insight into evolving customer wants and its confidence to buck convention.

The approach to delivering distinct interior designs was inspired, in part, by smart engineering. For example, the modular architecture of the F-150's instrument panel - a design shared across the range - is the foundation for the flexibility that makes a new F-150 Lariat or F-150 FX4 stand out so distinctively from other series derivatives.

Using this modular architecture freed designers to achieve distinct interior executions for each of the five series, using different colors, materials, textures and features while retaining the essence of the design across the range. For designers, this approach is about design coherence. For engineers, it's smart engineering because it rationalizes the investment required for tooling and testing. For customers, it means Ford offers a pickup with distinctive F-150 Tough Truck style that fits their lifestyle.

Similar differentiation can be found on the exterior of the all-new F-150. The new exterior design is well suited to different series executions - from the basic workhorse F-150 XL to the richness of F-150 Lariat. Ford's attention to detail in the initial design and engineering has provided the architecture for flexibility. Examples include the confident new grille design and bumper accents, which are executed differently across the series range.

Additionally, every F-150 model, regardless of trim level, incorporates a lower body feature line that serves as the point of differentiation for higher series models, allowing for two-tone paint and differing front-end treatments while retaining design coherence across the range.

FLEXIBLE MANUFACTURING

Ford continues to improve its manufacturing capabilities, and has made substantial gains in the area of flexible manufacturing. The company is introducing a new flexible manufacturing capability at its three F-150 assembly plants in the United States in conjunction with the introduction of the 2004 F-150.

Ford's Norfolk (Va.) Assembly Plant, Kansas City (Mo.) Assembly Plant and the new Dearborn (Mich.) Truck Plant will pioneer next-generation flexible manufacturing systems that are geared to producing the diverse new F-150 product range and give the Blue Oval the ability to respond to future changes in market segmentation.

Body shops in all three plants will employ an industry-first system of standardized cells or modules, all built from a select group of components. Only product-specific tooling needs to be changed or computers and robots re-programmed to launch new products.

"With increasing market segmentation, Ford's new flexible assembly system means the company can react more quickly to shifting customer demand," said Al Ver, vice president, Ford Advanced Manufacturing Engineering. "The company will be able to produce a wider variety of vehicles, change the mix of products and options, and change volumes - all with minimal investment and changeover loss."

Ford's new system standardizes the assembly process, which improves productivity through reduced changeover downtime. Standardization helps improve quality through increased repeatability. Plus, improved ease of access results in improved safety and ergonomics for operators and maintenance crews.

Flexibility in the body shop is the most important component of flexible manufacturing because of the complexity and cost of the operation. Ford's new flexible body shop system will cost less than both traditional body shops and other flexible systems, which generally are at a premium.

The new body shop will be able to handle two distinct platforms while producing different derivatives off each platform. The lines can be configured to accommodate front-wheel-drive, rear-wheel-drive, unitized body and body-on-frame vehicles.

The same type of standardization found in the new body shops also will be employed in final assembly. Final assembly operations will have a standard sequence, with standardized workstations that can be changed or modified quickly and easily to accommodate new vehicle options or features.

Norfolk Assembly Plant is serving as the lead plant, alongside the proven pickup producer, Kansas City Assembly Plant, to begin flexible production of the 2004 F-150.

Beginning in 2004, the Ford F-150 also will be built at the new Dearborn Truck Plant now under construction at the legendary Ford Rouge Center in Dearborn, Mich. The new flagship of Ford's lean and flexible assembly plants, it will have the capability of interchanging three vehicle architectures and producing up to nine different models, if needed.

The new assembly plant construction is the centerpiece of one of the nation's largest industrial redevelopment projects. For more than 85 years, the Ford Rouge Center represented a key element of Henry Ford's vision of vertical integration - a self-contained manufacturing complex, where most vehicle components were made from raw materials and assembled into a finished product.

F-150: MORE CAPABLE THAN EVER

A responsive drive? Yes - even fun. Quiet? Yes - and with a great engine sound. Compromising on its core capabilities? No way.

The all-new F-150 pickup truck is not only tough, capable and versatile, but it also has better interior spaciousness, features that contribute to ergonomic ease, and new levels of overall refinement than before. The combination makes for a calm, quiet confidence that all drivers, from contractor to CEO, will appreciate.

Cargo capacity and towing performance

Each of the new F-150 cargo boxes - in 51/2-, 61/2-, and 8-foot lengths - is more than 2 inches deeper than before, increasing usable volume and customer benefit.

The total cargo volume of the 61/2-foot box, for example, is 65 cubic feet, which is nearly 12 percent better than the current F-150, 13 percent better than Chevrolet and a 42 percent larger than Toyota's 6-foot box. When hauling wood chips, soil or yard clippings, the extra capacity could help save a trip or two.

The all-new F-150's chassis and powertrain make pulling a trailer easier than ever. Its laterally stiff new rear suspension, precise steering and a stiff frame and body provide confidence while under way. Powerful brakes enhanced by standard anti-lock control and electronic brake force distribution maximize stopping power.

With the seamless calibration of the 5.4-liter, 3-valve Triton™ V-8 engine and new 4R75E automatic transmission, F-150 owners also will appreciate the smooth nature of the trailer- towing experience. "Hitching," an irritating phenomenon on some trucks in which the trailer and tow vehicle seem, at times, to fight each other to maintain the desired speed, doesn't plague the all-new F-150 due to the detailed attention to powertrain compatibility and fine calibration.

The electronic throttle control system used on both Triton V-8 engines features a unique 4x4 Low calibration for optimum vehicle control in off-road situations. Compared to cable driven or electronic pedal-follower systems, Ford's state-of-the-art torque-based electronic throttle control system allows precise torque control in 4-Low at low speeds and low throttles.

With a maximum tow rating of 9,900 pounds and maximum payload capacity of 3,000 pounds, the new F-150 is the most capable full-size pickup under 8,500 pounds.

The Towing Group includes a 7-pin trailer wiring harness, frame-mounted hitch receiver and a heavy-duty electrical/cooling package.

Tough design

Half a century of truck leadership comes by toughness, not chance. The all-new 2004 F-150 takes "Built Ford Tough" to the next level.

At the truck's core is a stout fully boxed ladder frame with hydroformed front rails. The critical cross members are joined to the rails with a stiff "through-rail" joint to prevent localized flex. The brackets that attach the suspension, body, and powertrain to the frame are "wide footprint" designs that maximize the size and stiffness of the attachment point.

The sturdy frame - which is approximately nine times stiffer in torsion than the 2002 F-150 - is engineered to provide the stiffness necessary to help allow the suspension isolate the cabin from the most punishing treatment.

Likewise, the body is approximately 75 percent stiffer. Both it and the frame stiffness help ward off the kind of squeaks and rattles that could mar the driving experience of a high-mileage pickup. For the all-new F-150, the most aggressive use yet of structural adhesives on a Ford truck helps to spread loads over the length of a seam, helping to minimize stresses at the spot welds and helping to maintain long-term body stiffness.

Joining the frame and body are durable shear-style mounts. In addition to providing three-axis tunability for an improved ride, the tubular mounts spread forces across the entire bushing surface, contributing to more consistent long-term performance and protecting the rubber inside from deterioration. After a durability test that simulates 150,000 miles of severe duty, the shear-style mounts typically degrade less than 10 percent, compared with degradations of up to 60 percent for traditional compression-style mounts. This helps the 2004 F-150 perform at its best for the long haul.

Rust protection

The new F-150 has undergone an extensive corrosion resistance program for the chassis and the body. Virtually all body panels feature double-sided galvanized steel, except for the roof, which is galvanized on one side only, and the hood, which is aluminum. A full phosphate dip plus High-Edge E-Coat systems and durable paint help to protect most of the body and chassis components.

Door lower hem flanges are sealed with a special weather-resistant adhesive.

The frame is given an E-Coat finish. The front edges of the hood receive a thicker layer of primer before painting, and clearcoat paint and a PVC coating are sprayed on the lower bodyside for extra chip and corrosion protection from stone pecking.

The exhaust system is stainless steel and is manufactured to withstand the harshest weather.

Prototypes complete a 17-week corrosion test at Ford's Arizona Proving Ground that comprises a gamut of torture, including Saltbath, Humidity Chamber and Drying Chamber. Sixty cycles of this testing are the equivalent of six years of abuse in Canada's rugged Maritime Provinces. Prototypes of the 2004F-150 have been subjected to hundreds of cycles.

All told, the new F-150 has endured the equivalent of more than 5 million cumulative miles of testing. And as expected, the all-new F-150 has withstood the harshest tests over time with the durability that is typical of F-150.

Smart ergonomics

Contractors, tradesmen and personal-use buyers may have different needs and wants in their F-150, but each use the truck as a tool - to get the job done, to get their gear to the recreation area or to get to work between weekends. Ford knows that any good tool is easy to use, and engineers have worked extensively to help ensure that all of its customers find the all-new F-150 to be a good "fit."

People come in all shapes and sizes, of course, and the all-new F-150 reflects that fact: It's designed to accommodate a 25th-percentile woman (approximately 4'10" tall) as well as a 99th-percentile male (approximately 6'4"). The cabin is wider than ever before and its front seat is roomier, yet the door armrests are large enough for smaller persons to use comfortably. Grab handles and available running boards assist during entry and exit, and optional power-adjustable pedals join a standard tilt steering wheel for customization of the driving position.

The standard tailgate assist feature helps lesser-statured people operate the large tailgate, and the running boards were moved lower and further outboard to be more useful for stepping up into the cab.

Large exterior door handles are an intuitive full-grip style that ensures an easy grip and maximum pull even while wearing large gloves. Likewise, the underhood release lever, large and painted yellow for visibility, is easy to use, even with gloved hands.

Interior storage is flexible and abundant. A dash-top bin holds small, frequently used items like pens, cell phones and parking passes, while full-length map pockets on all doors have large capacity. The front door pockets are divided into forward and rearward sections, and each includes a cup holder large enough for a 20-ounce water bottle. F-150 models equipped with the optional front center console have a deep storage bin, coin holder, four additional cup holders and a rear 12-volt power point.

Core to the design of primary and secondary controls were two objectives: ease of use and cohesive appearance. Experts from Ford's ergonomics laboratories used computer modeling to help ensure that all of the driver's instruments and frequently used controls are easy to see and operate. The computer allows designers to test functions objectively, using a wide variety of electronically generated human shapes. In addition, a virtual reality system brings a digital interior to life before prototypes are built. The simulation can emulate the visual feeling of smaller or larger individuals so that engineers can configure the vehicle for compatibility for a broad range of human statures.

Other ergonomic features include an optional power-sliding rear window that eliminates the potentially awkward reach in longer cab lengths, easy-to-operate air registers, an oversized volume knob on the audio system, and a four-wheel-drive knob that visually matches headlamp, power point and climate controls on the instrument panel but is tactilely differentiated with molded-in ribs.

Visibility also was a key priority. The drop-down beltline, sculpted windshield pillars and oversized mirrors aid visibility. Studies done on the instrument panel materials and design reduced so-called "veiling glare" in certain lighting conditions and character heights on the speedometer were increased to make them more legible.

Low noise

Essential to meeting Ford's goals for the best driving experience available in a pickup truck was engineering quietness into the cabin from the earliest stages of the program.

A quiet passenger cabin helps driver and passengers to stay alert, to more easily hold a conversation and to arrive relaxed. "Quietness is perhaps the most influential factor in perceived quality and overall customer satisfaction," said Chris Kolarik, F-150 noise, vibration and harshness supervisor.

The F-150 team tackled cabin noise from a holistic, systems perspective, influencing design, materials selection, manufacturing processes and above all, fanatical attention to detail.

As a result of their efforts, the F-150 cabin has highway cruise noise levels that are 2 sones quieter than the previous segment leader. While driving on coarse country roads at more moderate speeds, overall interior sound levels are 2.8 dBA lower. During wide-open-throttle acceleration, the "speech articulation index" - a measure of how easily one can hold a conversation - is 5 percentage points better than the nearest competitor, above 3,500 rpm.

Body sealing and sound absorbing techniques

To combat unwanted noise, the new F-150 has fully inset doors with improved seals, thicker front side windows, a laminated dash panel and noise-blocking air extractor vents at the rear of the cab. The "Quiet Steel" dash panel is made of a new metal and mastic laminated material that reduces noise transmitted from the engine compartment.

New double door seals - even at the bottom edges of the doors - and 25-percent thicker front side glass combine to reduce wind noise.

Body leakage, a measure of how much air leaks out of the cabin, has been reduced. These air leaks can translate into wind noise. During the development process, engineers identified these leaks by pressurizing the cabin and then determining where air was escaping.

The leaks were then corrected with a variety of tools like expandable foam or heavier sealing.

For example, new gaskets seal the door handles better to reduce both wind and road noise. Structural adhesives used in the cab floor were a key contributor to the reduction of cabin air leakage.

At the assembly plant, 6-Sigma "Black Belt" quality experts work to reduce build variability with the goal of reducing sources of noise, vibration and harshness as well as optimizing installation of sealing and sound-deadening materials.

Body isolation

The stiffness of the frame, body and powertrain contribute to the calm, quiet ride by allowing the mounts at their attachment points to perform at their best. The shear-style body mounts, for example, are specially tuned to specific frequencies, and the stiffness of the frame and body is critical to their ability to isolate passengers from noise, shake and vibration.

Liquid-filled engine mounts or "hydromounts" stop much of the engine's noise and vibration before it can reach the passenger compartment. Because their damping rate depends on the frequency and amplitude of the vibrations, they can simultaneously provide soft isolation against higher frequency, lower-amplitude motions - the kind that engines make at idle or while accelerating - yet provide stiffer control of the powertrain in response to jarring on a bumpy road.

Features and content

With the all-new F-150, all series - from the workhorse XL to the top-spec Lariat - contain distinctive comfort and convenience features. Among the key features, by series (each item in the list is the same for the higher series unless noted):

XL:

Rear access doors on Regular Cab
AM/FM radio with clock
Cloth 40/20/40 split front bench seat
17-inch gray styled-steel wheels
Air conditioning
Tilt steering wheel
Lockable tailgate

STX:

AM/FM stereo with single CD
17-inch sporty cast aluminum wheels
Optional AM/FM stereo with 6-disc in-dash CD changer with audiophile

XLT:

Overhead rail storage system
Premium cloth seating - 40/20/40 split bench or optional captain's chairs
Power windows, including power second-row windows on SuperCab and SuperCrew
17-inch cast aluminum wheels
Power mirrors
Remote entry key fob and optional driver's side keypad
Autolamp
Delayed accessory power
Outside temperature/compass display
Speed control
Optional AM/FM stereo with 6-disc in-dash CD changer
Optional power-sliding rear window
Optional power moonroof
Optional defrosting rear window

FX4:

Unique interior palette with leather-wrapped steering wheel, metallic trim and unique instrument cluster
Standard driver's side keypad
Sporty cloth 40/20/40 split-bench seat
17-inch machined aluminum wheels
Optional 18-inch machined cast aluminum wheels
Optional sporty cloth or sporty flow-through console and floor shifter

Lariat:

Unique interior palette with leather-wrapped steering wheel, simulated woodgrain trim, and unique instrument cluster
Leather 40/20/40 split bench seat
AM/FM stereo with cassette and single CD
18-inch bright aluminum wheels
In-dash message center
Steering wheel audio/climate controls
Electronic automatic climate control with integrated optional heated seats
Deluxe mirror package - power heated side mirrors with integrated turn signal repeater
Power-adjustable pedals
Optional leather captain's chairs with flow-through console and floor shifter

F-150 options available on most trims include power-adjustable pedals, a reverse sensing system, axle, payload and towing upgrades, skid plates and running boards.

Story by Ford Edited By Maximum-Cars.com