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I think it was a game of semantics in 99 to give a distinction to the new line of F-250 and F-350 trucks. The term heavy duty typically referrs to the 3/4 and 1 ton models of a standard chassis (think of the Dodge Ram you have the 1500, 2500, and 3500 but they all look the same). Ford did something different and made their 3/4 and 1 ton trucks look totally different while (I think) just in '99 still making an F-250 based on the F-150 chassis. Also all the Super Duties have a weight rating significantly higher than the name would imply (ie an F-250SD is rated in the neighborhood of a true 1-ton). I'm not entirely sure and I'm sure someone will not hesitate to correct me if I'm wrong, but I think this is the basic reasoning.
Here's some info I've gathered over the past few years:
The 1980-1996 body style had 3 ratings, Light Duty, Heavy duty and Super Duty. (1997 only had HD and Super Duty)
You could get a Light Duty F250 with a 6 cylinder 300cu/in or a 302 V8. They had a 10.25" Sterling semi-floating axle rated at 5300 lbs. Ford quit making those in 1996. For 1987 and later, the manual transmission in the LD's was a 5 speed Mazda M5R1 or M5R2 similar to the F150's. In 1988 you could also get an HD 4 speed manual. Later, you could get the same ZF S547 as the HD. The auto was either the C6 (3-speed) or the E4OD (4 speed OD) for the 300 I6 or the AODE/4R70W/E4OD (4 speed OD) or a C6 (3-speed) for the 302 V8 depending on the year.
The Heavy duty was made until 1997 and was replaced by the current Super Duties. You could get an F250 or F350 with the 351, 460, 6.9L diesel (1984-1987) and 7.3L diesels. Those had the full floating Sterling 10.25" axle for both SRW and DRW. In 97 the HD's could have a 3.55 or a 4.10 axle ratio. The GWR went from 8600lbs (F250) to 11000lbs (F350 DRW) The Manual transmission was either a ZF S542 (1987-1994) or a ZF S547 (1995-1997). The automatic transmission was either the C6 (3-speed) and also the E4OD (4 speed OD).
The F-SuperDuties where above the F-350 in GWR, they were 1 1/4 tons. The 1997 F350 DRW had a GWR of 11000 lbs while the F-Super Duty was rated at 15000 lbs. They also had a Dana 80 rear axle and monobeam front axle with leaf springs, even on the 2wd. You could only get the FSuper Duty with a 7.3L Diesel or a 460 gas engine. For 97, the only rear axle ratios offered were 4.63 and 5.13. The transmissions available were the ZF S542 and S547 5-speed manuals and C6 and E4OD automatics.
To confuse everything, Ford made the F250LD using the 1996-2003 F150 body from 1997-2000. They had a stiffer frame and a semi-floating Sterling 10.25" axle with 7-bolt wheel pattern rated at 5300lbs. Because of low demand, 2000 was the last year for the F250LD. Now you can buy an F150 with the 7700lbs package which has the same frame and axle as the old 1997-2000 F250LD. On 2001 through 2003's, the tailgate F150 badge has a little red "7700" under the 150 part. The 1997-2000 F250LD were available with either the 4.6L V8/4R70W auto or the 5.4L V8/4R100 auto. The 2001-2003 are only available with the 5.4L V8/4R100 auto.
The 1999-current Super Duties are available in F250 3/4 ton(8800lbs GWR) F350 1 ton (SRW 9900lbs and DRW 11500lbsGWR) F450 1 1/4 ton(15000 lbs GWR) and F550 1 1/2 ton (17500-19000 lbs GWR). F250 and F350 SRW have a Sterling/Visteon 10.5" full floating axle, F350 DRW and F450 have a Dana 80 11.25" full floating axle and the F550's have a Dana 135 14.38" full floating axle in DRW only. They are available only with the V10, 7.3L or 6.0L diesels while the F250 and F350 have the 5.4L V8, V10, 7.3L and 6.0L diesels available. The transmissions are ZF S547 5-speed manual (1999-2001 gas and 1999-2000 diesels), ZF S6-650 6-speed manual (2002-current gas and 1999-current diesels), 4R100 4 speed automatic (1999-current gas engines and 1999-2003 7.3L) and, Torqueshift 5-speed automatic. (2003-current 6.0L diesels).
Did I forget anything or get anything wrong? I'm sure I did.
Thanks Bordaine, 10-lug and rear disc brakes for the 1992-1997 F Super Duty. Do you know if that was on a Dana 80 by chance? More things we can add to the 1980-1986 's (for which I have very little documentation) is the BW T18 and T19B 4 speed manuals on the F250LD's and the NP435 4-speed on the HD's. Ford switched from the T18 and T19 to the Mazda M5R1 5-speed in 1988 although you could order the T18-4 for just 1988 on the f250LD's. The ZF S542 on the later F250LD's had a concentric slave cylinder while the ones used on the HD's was an external slave cylinder like the 1999-2004 Super Duties. I'm not sure when Ford quit using the Mazda in the LD's. Anyone know?
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