Ford F-150

To stave off competition in the light-truck segment, Ford has improved upon its perennial best-seller by giving it a stiffer fully boxed frame, a unique rear suspension design, a more powerful 5.4L V8, and a variety of interior refinements.

A pickup truck that combines toughness, capability, and dependability with a level of refinement not seen before in the segment was the goal of Chief Program Engineer Frank Davis while working on the redesigned 2004 Ford F-150.

Davis and his engineering team accomplished all aspects of that goal largely through a new chassis design. Improvements in ride, handling, and quietness are due in part to a solid fully boxed frame with hydroformed front rails. Hydroforming was used for the sections of the front rails that bear the loads of the front suspension, which is “probably the most critical portion of the frame” for providing a consistent riding experience, said Jim Baumbick, Manager of Truck Vehicle Integration for Ford.