Background (optional read)
I realized how most of the info i wrote in the first 3 paragraphs wasnt really all that usefull info.

Well i should start out by saying that i've never been one to mod any car/truck very much, I do know how engines work, I know the basics, however, I wouldn't be called a "Truck" guy by any strech of the word. In my field I know quite a bit about engines, but none of them are actually on a truck, they spin pumps n' such.

A few years ago i had leased a 2007 Chevy Silverado, and I loved the truck. The only thing i ever did to it was put a new muffler on it to give it a slightly more agressive sound to it without being annoying to everyone else who doesnt give a damn about trucks. Eventually the Lease ran out and they wanted more for it then it was worth, so obviously i just gave it back.

I have never been a fanboy of any particular truck make. I drove a chev because that particular truck was a good deal at the time. I do have to say that I thought it was a nice truck to drive, and never gave me any problems. Then again, no truck that is under 3 years old should ever give any problems. However, i really liked the look of the fords inside and out, so i decided to give Ford a chance, and began looking for months for a newer used Ford truck.

Actual Question/Problem

Anyways long story short, I drive a 2008 Ford F-150 FX4 Truck now, and I am really happy with it so far except for a couple of things. I noticed the engine has slightly less power then the chev when driving at highway speeds (To pass people). Which would have been fine(For me personally) if it also got better gas mileage then the Chev. It however does not, and gets 5-6 MPG(Highway) less! then the Chev did.

I was talking to a Ford enthusiast that i work with and he said viechles, Not just Ford, but all makes, Have size restrictions in their intake, tuneing, exhausts that give them less power and gas mileage then they potientially could get.

My question is Firstly,

Is this correct? Can I spend a few bucks on a Tuner, Intake and exhaust and gain 5 mpg? In my eyes this would be a no-brainer. The fuel savings would more then make up the price of the items over time.

Second Question,

If this is Correct, what the hell is Ford doing? Why wouldnt they spend a bit more on their production and have a truck that has more power and mileage then anything else on the market? Doing something that costs us $1000-$2500, they could do for half the price or less due to mass quantity. It is this alone that makes me question the advice that i recieved, as i couldnt see a manufacturer saving a couple bucks on production and not having perhaps one of the biggest selling features on the market with todays high oil prices. At the very least have it as an option, you could pass the cost right to the consumer, I would imagine a lot of people would do it if you could price it slightly less then aftermarket cost.

Thank you,

As I just finished reading my own post, it occured to me that in 2009 - 2011 perhaps they have made some improvements in this reguard, I know the new 2011 commericals brag about 30 mpg, but they are also listing 2wd truck mileage...

Forgive me for the weirdest forum post format..

 

You need to post more info on your truck. What engine? Trans? Final drive gear ratio? 4X4s have never been known for getting good mileage. All the extra parts rotating from the transfer case to the front driveshaft, to the whole front axel. Also the final drive is usually lower then the averate PU. You have to put on bigger tires to offset this but that hurts mileage too due to increased wind resistance.

 

Well, its a 5.4L V8 automatic trans. Im not sure what the gear ratio is.

Reguardless, im not looking for exact numbers. Just wondering if I can gain a few mpg changing out thoes 3 things.

 

You can blame fleet emissions targets for some of the problem here, the exhaust emissions produced by any particular engine is ultimately limited by the design and in some cases this results in a production engine that doesn't produce as much power as it could, it takes some re-engineering to increase power without also increasing emissions so a few ponies get left in the stable. Noise control is another area that can eat into power output as well and this is something the engine design department may not have any control over, Ford trucks in general are quieter than the competition and that means the intake and exhaust systems are more restrictive.. sad but true.

On another note, the transmission and axle gear ratios have a big impact on the apparent road power of a vehicle and Ford has a tendancy to install more high(numerically low) gears in their trucks. So if for example your current truck has 3.31 axles and the Chevy had 3.73 that would certainly make the chevy feel more powerful.. and it may also produce better gas milage.. just depends upon the whole package and driving conditions.

Bottom line of all this is yes you can gain power and milage with intake, exhaust, and tuning upgrades on these trucks, I don't know if you can get 5mpg but you will gain some.