I'm considering replacing my '96 F250 and my wife's Subaru with a newer used F250 or F350 crew cab. I'd want diesel and 4X4, she wants automatic and fully loaded. Some questions.
Is the automatic and the push button transfer case as bad as I think it is? I've never owned an automatic truck and those things seem weird to me
What's the best rear end gears for occasional medium weight towing? Rarely more than 10K lbs
Can I tow a 5th wheel with a shortbed?
What sort of fuel mileage should I expect when running light?
Are there better years to look for and why?
Sorry for all the silly new guy questions, but I've putting most of my time and effort into my '70 and haven't kept up with the newer trucks.

 

The 6.0L had a bumpy start in the '03-04 model years. Some would tell you to avoid them, but I, personally, am in the group that suggests basing the purchase decision off of an Oasis report. The '05-'07 years went to a coil spring setup in the front end for a tighter turning radius and larger disk brakes at all four corners.

The TorqShift is arguably one of the best automatic transmissions in service on the heavy duty truck market. Aside from being mechanically sound, it has the brute strength & fortitude to withstand just about any service life you would throw at it--be it daily commuting or max payload long hauls.

The Electronic Shift on the Fly (often called the ESOF) four wheel drive system is a decent sytem, but not totally without fault. The hubs have an "AUTO" & "LOCK" position. While in "AUTO" position, the front axle is engaged with a vacuum system whenever the in-dash switch is placed into 4x4 Low or 4x4 High positions. The primary compaint & failure in the four wheel drive system is a mix between loss of vacuum and the automatic front hubs getting stuck. The end result is either the front axle not engaging when the ESOF switch is flipped to a 4x4 position, or the front axle not disengaging as intended. Preventative maintenance is your best insurance policy here. Routine maintenance of the front hubs, inspecing the vacuum line system, and occasionally placing the truck into 4x4 will help ensure that the system will be ready when you need it. There are also a fair number of folks that eventually swap to a manual locking hubs to eliminate that next "weak link" in the system.

Most Super Duties come equipped with 3.73 gears, and those will do fine with the towing you are suggesting. Depending on the type of towing, terrain, etc., it may be worthwhile to step up to 4.30 gears. These were available in Super Duties that came equipped with the "Tow Boss" package.

Yes, you can tow a 5th wheel with a short box. The real limitation will be between the trailer configuration and clearance between the front of the trailer & the cab during turns. As a loose reference, measure from the center of the pin to the front corners of the trailer, and then check that measurement against an imaginary point centered (left to right) in the box, directly above the rear axle.
You might also want to double check this with a visit to your local RV/camper sales, and with the folks that lurk a bit further down the main forums page (Misc./Towing, Trailers And 5th Wheels) here on FTE.

Fuel economy varies pretty widely, and your own right foot will be the biggest factor in the equation. That being said, I would hazard to guess that with no real load you would get about 13-15 MPG in the city and 16-18 on the highway. With a load, those numbers are going to drop off, but just how much is really dependent upon the terrain, what you are towing/hauling, and your right foot.

I think that pretty much covers your first round of questions. Good luck & happy truck shopping!

 

I agree with Deluxe05, depending on what you want how much you can afford. If you want an older truck the 7.3L Powerstroke is also a great motor very reliable, the transmissions are fine especially in light towing if you wanted to do heavy towing I'd suggest a shift kit or upgrade the transmission. As far as the 6.0l goes if you want one make sure its and 05-07 and do an oasis report to make sure it's not a troubled truck. It seems that the 6.0L if they had problems they always will. The other downside to the 6.0L is sometimes the problems don't arise till later in life, so it's kind of crap shoot. As far as the transmission in the 6.0L it's far better then the 7.3L transmission for heavy towing.

The Electron Shift on the Fly, most say to avoid if possible just due to the problems that can arise, if you are getting a new truck it's going to be hard to find one with out ESOF. On the older trucks manual hubs are more common. Manual hubs are going to be the most reliable, but you also have to get out of the car to lock them in.

Most Super Duties come with 3.73 gears which is fine for what you are talking about towing. As far as fuel economy in varies my 7.3L get about 20 hwy if I drive nice and about 15-16 city. I guess I don't know what 6.0L get.

 

The Ford Super Duty automatic 4 wheel drive system (ESOF) has a number of weak spots. While they will not leave you stranded, they may keep you from using 4 wheel drive when you need it.

First, the vacuum operated hubs suck. A very common truck modification is to remove the ESOF hubs and install manual hubs.

Second, the vacuum solenoid that controls the system often fails. You hear of a lot of owners who have to replace the slenoid.

Lastly, the electric motor that shifts the transfer case fails on a regular basis. That is another frequently replaced part.

I drive manual hubs and manual transfer case trucks. It is not a huge deal. If you think you MIGHT need 4 wheel drive sometime during your drive, you lock the front hubs BEFORE you leave your driveway. Driving on any surface with your front hubs locked will not damage your truck.

When you need 4 wheel drive, you just pull the level back on notch and go. It's actually faster than the ESOF system. When the need for 4 wheel drive has past, you push the lever back to 2 wheel drive.

When you finish your driving, you can unlock the hubs. There is no need to get in muddy slop or slush to lock your hubs, unless you are somehow surprised by slippery conditions and the need for 4 wheel drive. That has happened to me once in over 10 years, I drove into a freak snow storm.

I have gone for weeks at a time with my front hubs locked, during the winter.

Tell your wife that manual hubs and a manual case are the most reliable systems and cost less.

 

Does anyone know if a mod has been done to remove electric motor and replace it with a stick(manual) ? on the PSD's

 

I started using the pushbutton shift on the fly system of Ford back in 86 and have stuck to it ever since with never a failure or problem. I like having the floor free or shift levers making it easy for someone to sit there<smile>. A one armed frind sold me on the SOF system back in 86 and I, like you, was skeptical at first but now I would never go back. Get the auto SOF and tow command system if you can. Those bells are nice. On my last SD I even sprung for a moonroof! Now I get rained on occasionally like in an open top jeep

 

From what everybods says it is a different transfercase and is not convertable.

 

I'm with bfloyd4445. I've had both the manual and the elec. trans. case. I neverhad a problem with either of them and I actually USE mine (maybe abuse a little) more than the average Joe. You can get the push button transfer case and have the manual/auto hubs. If you're on ice or snow you can just push the button and they'll engage by themselves or if you know you're going to get in some tough stuff, you can get out and manually lock them if you feel the desire. Believe it or not, because of my driveway to the house, I use my 4 w/d twice a day. Once coming down in the morning and once going up in the evening.

 

aint no fun getting out in he mud during a blizzard to flip yur hubs. I'd much rather just reach over and flip a switch while sippin a hot cup of coffee and listening to the howling blizzad outside.

 

I have had 2 4 wheel drive trucks, both shift on the fly, and one 4wd that wasnt. I absolutely hated the truck that wasnt shift on the fly. My problem was that if I got stuck, it would never go into 4x4, would just sit there and spin the rear tires. My shift on the fly goes in automatically...

 

Yep, u fall in love with em ASAP. Good stuff<smile>

 

Both my dads 99' and 03' SDs were at the dealer several times each after he bought them new. The ESOF was not working properly(Vaccum Leaks)

Took 4 trips to the dealer to fix the 99' and 3 for the 03'. After seeing that I went with the manual set-up on my new 04'.

The ESOF comes in handy, but what good is it if it doesn't work?

 

Did you get out and lock the hubs?

 

I'm just the opposite. I've had two truck with automatic hubs, hated it. I converted them to manual and won't get another.

Like I said, the key is getting the hubs locked if you think you MIGHT need them. Don't wait until you do need them. Around here, if snow is expected my hubs will be locked. If I am driving off road, especially if I don't know the route, hubs get locked.

 

It had automatic hubs and a floor shifter (chevy).