Ford F Series (tenth generation)

Development

In late-1989, during mid-stage development of a facelift due in late-1991 for model year 1992, Ford commenced the PN-96 program on a new truck platform and designated Thomas Baughman as chief engineer. In mid-1990, Andrew Jacobson was designated as design director for the PN-96 truck program. By 1991, designers had developed clay models indicative of car like styling, based on a new design theme. Despite the disapproval from focus groups towards "softer" styling, during 1991 and 1992 in concept design clinics, Ford management backed the "aero" design philosophy. The end result by Bob Aikins reached in November 1992 and frozen for production in February 1993, took the aero styling further with a rounded nose on the new F-series. The PN-96 mules went into testing 1993, with prototypes running from early-1994. Pilot production began in 1995.

1996–2003

Being the F-150's first major redesign since 1979, the redesigned truck went on a nationwide 87-stop tour to Ford plants and the external part suppliers in October 1995, prior to its release. To build anticipation for the redesigned truck, the 1997 model was released in January 1996 with the first ad campaigns airing during Super Bowl XXX. Because of the radical styling, Ford predicted from marketing clinics that traditional truck buyers would not receive the radical and car-like 1997 well, so it continued to produce and sell the previous 1996 model alongside the redesigned 1997 model for a few months.

A wide variety of body options were available: regular cab and SuperCab, standard or flareside boxes, and short or long beds. A new Lightning was introduced in March 1999, and Harley-Davidson and King Ranch versions were also created. In 2000, the SuperCrew cab was introduced with four full-size doors for MY2001. A Sport 4x4 model was introduced in 2000 as well, it featured the 5.4 triton, color matched bumpers and mirror housings, was available in regular cab and extended cab and came in only four colors; White, Red, Black, and Silver. In 2002, an FX4 model was introduced which came with skid plates,a carbon steel frame, Rancho shock absorbers, and specific 17" aluminum wheels along with more standard features that were optional on XLT. In 2003, a sporty STX trim package was introduced, aimed at younger truck buyers. The STX package featured color keyed front/rear bumpers along with clear lens headlights and integrated round fog lamps. The package also featured chrome step rails, 17" chrome wheels, and a Kenwood Z828 stereo was installed in place of the standard Ford radio. Also in 2003, a special trim package "Heritage Edition" version with special badging was produced to mark the 100th anniversary of Ford trucks, available only in the 139" wheelbase SuperCab body.

Sales of the F-150 surged in the tenth generation from 750,000 to over 900,000 in 2001 as the General Motors and Chrysler/DaimlerChrysler's Dodge Ram products lagged. Ford's sales dropped, however, for the final years of this generation as the redesigned Dodge trucks were released.

The new F-150 was Motor Trend magazine's Truck of the Year in 1997. A minor facelift was introduced September 1998, with minor interior updates for 1999 models. In February 2000, the SuperCrew was added to the lineup early in the 2001 MY (Model Year), entering production on December 13, 1999. Ford also manufactured a limited run of "Heritage" (differentiated from the 2003 "Heritage Edition") F-150s of the 2003 body style in 2003 (as 2004 model years) to finish out production.

This generation of F-150 was sold in Mexico until the twelfth generation 2010 model was released there.

Powertrain

A new lineup of improved efficiency engines were offered beginning for 1997. A 4.2 L OHV V6, based on Ford's 3.8 L Essex V6, replaced the 4.9 L OHV I6, while 4.6 and 5.4 liter SOHC V8s replaced the 5.0 and 5.8 liter OHV V8s. The 4.6 and 5.4 liter V8s were marketed under the name Triton and mark the first use of Ford's Modular Single Overhead Cam (SOHC) engines in the F-series pickups. Ford's own 8.8 IFS replaced the Dana 44 front end, while the Ford 8.8 rear remained. The Ford Sterling 9.75 axle was also optioned in heavy-duty versions. In 2000, the Sterling 10.25 axle became an option.

Engines:

Safety

This generation F-150 received an overall "Poor" rating by the Insurance Institute for Highway Safety (IIHS) in the frontal offset test, and was ranked the 2nd Worst Performing Vehicle behind the 1997–2005 GM U-platform minivans.

Ford has found that the cruise control system in many of their trucks could catch fire, because the switch system could corrode over time, overheat and ignite. Ignition was later blamed on spillage from the adjacent master cylinder. On March 5, 2007 Ford recalled 155,000 2003 full-size pickups and full-size SUVs for the defective part. During the previous two years Ford had recalled 5.8 million vehicles in because of the defective cruise control systems in trucks, SUVs and vans. That recall, one of the largest in history, covered vehicles from the 1994–2002 model years.

F-250

With the initial introduction of the new F-Series in the later half of 1997, only the F-150 was produced. To bridge the gap between the F-150 and the previous generation heavier-duty models (to be replaced by the Super Duty series for 1999), the light-duty F-250 was produced as a temporary model for 1997-1999. While externally similar to the F-150 (with the exception of its 7-lug wheels), the F-250 gained increased load capability from a heavy-duty rear axle and load-leveling rear suspension. The F-250 HD (Heavy Duty) was in the same series as the F-350.

After the introduction of the Super Duty version of the F-Series in 1998 as a 1999 model, the light-duty version of the F-250 was discontinued; the heavy-duty suspension continued on as the "7700" package for the 2000-2003 F-150 (noted on the tailgate emblem).

SVT Lightning

The SVT Lightning is a sports/performance version of the F-150, released by Ford's SVT (Special Vehicle Team) division.

1999–2004

In 1999, after a three-year hiatus, Ford SVT unveiled a new Ford Lightning powered by a modular SOHC 16-valve 5.4 L Triton engine producing 360 hp (268 kW; 365 PS) and 440 ft·lbf (600 N·m), with a factory-installed Eaton supercharger. The 4R100 automatic transmission was used, and the rear gear ratio was 3.55:1. The Lightning featured 18" wheels and Goodyear Eagle F1 295/45ZR-18 tires. The suspension system, which lowers the truck one inch in front and two inches in the rear, was also modified from the standard F-150. It retained the front short-and long-arm system with coil springs and a 31 mm solid stabilizer bar along with the rear solid axle with five-leaf springs and a 23 mm solid stabilizer bar. Monroe shocks were used from 1999–2001 then replaced with Bilstein shocks from 2002–2004.

For the 2001 model year, the engine design was slightly altered to produce 380 horsepower (280 kW) @ 4,750 rpm and 450 ft·lbf (610 N·m) @ 3,250 rpm. Also, the previously leaky intercooler was redesigned. This problem was addressed as a recall in earlier models. A cast iron block was used instead of aluminum. These upgrades were critical in order to support the 8 psi (0.55 bar) of boost delivered from the stock Eaton M112 roots supercharger. Another engine revision came in the 2003 Model Year when a weakness in the heads, the lack of sufficient threads for spark plugs, was addressed and fixed, although "piston slap", a mild knocking noise while the engine is cold, was still present. At the other end of the drivetrain, the final drive ratio was shortened to 3.73:1 with a 9.75 inch rear end in 2001. Also, in 2001 the drive shaft was increased in size to a 4.5-inch (110 mm) aluminum unit, from the previous 3.5-inch (89 mm) steel unit. The specially developed 295/45ZR-18 Goodyear Eagle F1-GS unidirectional tires were upgraded utilizing a new generation F1 GS rubber compound. With these engine and drivetrain revisions, Car and Driver magazine drove a Lightning from zero to 60 mph (97 km/h) in 5.2 seconds. For 2003, the Lightning's cargo capacity was raised from 800 lb (360 kg) to 1,350 lb (610 kg).

The second generation Lightning was initially offered in just Bright Red, Black, and White paint colors. The 2000 Model Year brought the addition of the Silver color to the lineup. In 2002, True Blue, a very dark blue, was offered, but replaced with a lighter Sonic Blue in 2003. The 2003 Model Year also saw the introduction of the Dark Shadow Gray color.

These trucks were manufactured at Ford's Canada Truck Facility in Oakville, Ontario until its closure. Special features specific to the Lightning included: