Extreme Makeover
With the competition in hot pursuit, Ford didn’t take any half measures to re-invent its new full-size pickup, the 2009 F-150
By Michael Goetz
Impressions
Apr 04, 2008
DEARBORN, Michigan — Ford was originally thinking mid-cycle review for the 2009 Ford F-Series, but went back to the drawing board when it became clear what the import and domestic competition were concocting in their full-size pickup laboratories.

Witness the all-new Toyota Tundra and GM twins (Silverado and Sierra) that came out last year, and the upcoming re-invented Dodge Ram that will come out later this year.

So now we have a virtually all-new F-Series to talk about. And for now it will just be technical details (and pictures), as actually road-going versions are still behind closed doors at the two places they’re built — Dearborn Truck, and Kansas City Assembly.

But we were lucky enough to be included in a pile of journalists that were trucked into the sprawling manufacturing site in Dearborn for an advanced — and thorough — briefing of the new truck.

When completed in 1928, at the confluence of the Rouge and Detroit rivers, Ford’s Rouge Complex become the largest integrated factory in the world. Today, it is one of the few automotive facilities still left in the world, where iron ore comes in one end and shiny new vehicles come out the other.

We were staged in the “Glass Plant,” so-called because one complete wall, and most of the roof, is made of glass. When built in 1922, it broke ground for bringing better light and better air circulation to the factory floor.

The Glass Plant has just been completely made over to become Dearborn’s New Model Quality Center, to make sure the launch of the 2009 truck goes off without a hitch. With the advent of digital processes, lots of manufacturing issues can be addressed before the assembly line starts running. Components include a virtual build centre, where engineers test how the parts and components should go together, and workstations that replicate various assembly line functions, for employee training purposes.

Ford now has such a quality center at each assembly plant in North America. Anyways, just the place to learn about the new 2009 F-Series…

Matt O’Leary, chief engineer of the 2009 F-150, told us that the mission statement for the truck was: Most Capable; Most Choice; Most ‘Smart’ Features.

To address capability, the frame was upgraded, by re-designing the front (hydro-formed) section, and by adding more high-strength steel to the rear “boxed” section. The frame is lighter, yet delivers 10 percent more torsional rigidity than its predecessor.

The most significant aspect of the suspension work was lengthening the leaf springs, and then moving them about a half a foot forward. As before, the Hotchkiss-designed rear suspension mounts the rear shock absorbers outboard of the rear frame.

A new engine option is a 24-valve version of the 4.6-litre V8. The 16-valve 4.6 V8 continues, as does the 24-valve 5.4, thought the latter has been tweaked for better output and E85 capability. (Ford was not yet ready to release power outputs).

The 4.2-litre V6 goes bye-bye, but Ford says the 4.6 V8 now has the same fuel economy as the 4.2. All engines are more efficient due to a new system that cuts fuel off during deceleration. Idle speeds are also lower (which required some NVH work, as vibration increases when revs dip that low).

While the four-speed auto is back again, a new six-speed can be mated to the 24-valve engines.

Towing capability and safety have been significantly ratcheted up. Available is a factory-designed and installed Integrated Trailer Brake Controller, as well as Trailer Sway Control, which automatically adjusts braking and throttle to bring a swaying trailer under control. Side-curtain air bags and AdvanceTrac with RSC (Roll Stability Control) are standard.

Customer feedback decreed that the new truck “must look like a truck.” You’d think that would be obvious, but I guess it points things to the less effete side of the design palette. Hence the new in-your-face grilles with huge crossbars, a steel bumper, high nose/big chin and power-dome hood. Overall, it has the similar tractor-trailer type vibe as its big brother, the HD Super Duty.

In profile, you’ll notice very pronounced wheel arches and the tiny “tail” on top of the tailgate, which actually nets some aerodynamic slipperiness. Part of the look is a big-wheeled stance, and you’ll now be able to order a wider variety of larger wheels and tires, including many 20-inch packages.

Ford also came up with a new F-150 logo, because, it said, others ripped off the old one.

Feedback revealed that truck buyers need lots of choice, because their vehicles are used for specific functions, so now there are 35 different ways you can order an F-150.

There are now three cab styles, four box options, and seven full trim lines: XL, STX, XLT, FX4, Lariat, King Ranch and Platinum. Some have exclusive grille treatments, and all have their own wheel designs (“wrench” for FX4, “wagon-wheel” for King Ranch, etc.). XL, STX, and FX4 all have blacked-out grilles. The new STX is targeted at young dudes who more style, but can’t, or don’t want to, go way up-market. As before, FX4 is the full-on off-road ride.

The mid-range XLT features a chromed grille. As before, Lariat is full-on luxury, but now has two hi-lux mates. The all-new Platinum (satin chrome grille) is positioned as a tough truck, with a luxurious/urban vibe. King Ranch, previously a package, has now been promoted to full-model status. There is an actual King Ranch in Texas, which is famous for its leather. As such, this model features lots of the stuff, in that black/brown combination that is so fashionable at the moment.

These days the pickup wars are fought much like the minivan/people-mover wars: Players are constantly upping the ante on how many new, novel features and/or space utilization measures they can bring to the table. In Ford-speak these are referred to as ‘Smart Features’ and they include:

 

  • A new interior, with a flow-through console large enough to stow two or more laptops. The lockable console also has various sections, including one for file folders.

     

     

  • A larger SuperCrew cabin that features flip-up second-row seats, and a completely flat rear floor to create 1,631 litres (57.6 cu-ft) of space behind the front seats — enough to facilitate the stowage of a 52-inch flat screen TV (which all real truckers need for survival).

     

     

  • More than 30 interior storage areas, designed for contain such items as cell phones, MP3 players, gate access cards, etc.

     

     

  • Dash-mounted USB port and auxiliary input, and one 12-volt outlet on the dash and one in the centre console.

     

     

  • Newly-designed cargo management system than can support up to 600 pounds per cleat.

     

     

  • Optional “Midbox” storage system.

     

     

  • Tailgate step, as first introduced on the Super Duty.

     

     

  • Box-side step that extends out from under the box to make it easier to access items in the cargo bed.

     

     

  • Bed extender that, when not needed, can be stored on-board without losing any functionality of the bed.

     

     

  • Capless fuel-filler.

     

     

  • Available Microsoft SYNC system, which can wirelessly link all your personal communication and entertainment devices to the vehicle, and allow them to be controlled through voice commands.

     

     

  • Available voice-activated navigation system, which can be optioned with new Sirius Travel Link for real-time traffic and accident data.

     

     

  • Available 700-watt Sony audio system with 5.1 surround sound and 10 speakers.

     

    The 2009 trucks will start showing up on Canadian lots this fall. In the meantime the 2008 trucks will continue to fill the pipeline.

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