Why did Ford stop using I-beam suspension?
Ford phased out the traditional I-beam front axle in favor of independent front suspension across most of its modern lineup. The shift followed a broader industry move toward better ride quality, sharper handling, and safer, more efficient packaging. This article explains what the I-beam setup was, why the change happened, and what it means for today’s Ford vehicles.
Understanding the I-beam suspension and its limitations
The I-beam front suspension refers to an older, solid-axle arrangement in which the steering and wheels are carried by forged or cast I-shaped beams connected to the frame, typically using leaf springs or simple coil/arc springs. While rugged and relatively simple to manufacture, this design tends to deliver heavier unsprung weight, more pronounced camber changes as the wheels move up and down, and less precise handling on rough roads. Modern independent front suspensions separate each wheel’s motion, allowing better tire contact with the road, improved ride quality, and more stable handling through corners and over irregular surfaces.
Ford’s historical usage
Ford used I-beam-style front axles in many mid-20th‑century models and in certain truck configurations. Over time, Ford, like most automakers, began adopting independent front suspension across most of its passenger-car lineup. Some rugged or specialized trucks retained heavier-duty I-beam–type arrangements longer, but the broad industry trend drove Ford toward modern independent designs for mainstream vehicles.
Why Ford stopped relying on I-beam suspension
The shift was driven by multiple, overlapping factors that affect both performance and manufacturing. The following list outlines the primary considerations that pushed Ford away from I-beam designs:
- Ride quality and handling improvements: Independent front suspension reduces camber loss and bump steer, delivering a smoother ride and more predictable steering on uneven pavement and during spirited driving.
- Better tire contact and stability: Allowing each wheel to respond independently helps maintain tire contact with the road, improving grip during cornering and over rough surfaces.
- Safety and crash dynamics: Modern suspensions enable more stable braking and predictable dynamic behavior, contributing to safer handling and energy management in crashes.
- Packaging and interior space: Independent designs can free up space around the engine bay and undercarriage, enabling more efficient packaging, cooling, and crumple zones.
- Manufacturing and component efficiency: As tooling, parts sharing, and manufacturing processes evolved, independent suspensions offered opportunities for standardization across models and platforms, reducing overall costs over time.
Ultimately, Ford’s move away from I-beam suspension reflected a deliberate industry-wide shift toward greater comfort, improved safety, and better manufacturing efficiency. In today’s market, Ford’s mainstream cars and SUVs rely on independent front suspension, with legacy I-beam configurations largely limited to historical notes or restoration projects rather than current production.
Current status and legacy
In the 2020s, Ford’s passenger cars and most SUVs predominantly use independent front suspension, aligning with global automotive standards for ride, handling, and safety. Some older or heavy-duty trucks historically employed Twin I-Beam or other I-beam–style layouts, but contemporary models have largely moved to more advanced independent designs. The I-beam era remains a chapter in automotive history and a point of reference for engineers studying suspension evolution.
Summary
The transition away from I-beam suspension at Ford mirrors a broader industry evolution toward independent front suspension. The change was driven by the demand for better ride quality, enhanced handling, improved safety, and more efficient manufacturing. Today, Ford’s mainstream lineup reflects those priorities, with the I-beam design largely relegated to history and restoration rather than active production.
Does Ford still use the twin I-beam suspension?
No, Ford does not still use Twin I-Beam on its current light-duty trucks; that suspension was phased out in the late 1990s for the F-150 and replaced with A-arm suspension. However, the rugged Twin I-Beam system is still used in two-wheel-drive versions of its larger, heavy-duty Super Duty trucks, such as the 3/4-ton and 1-ton models.
- Light-duty trucks: Ford replaced the Twin I-Beam with a more modern A-arm suspension in the F-150 and other lighter models to meet fuel economy standards and for improved handling.
- Heavy-duty trucks: The Twin I-Beam design is still used in the two-wheel-drive versions of the heavier Super Duty pickups, including F-250 and F-350, because of its durability and load-carrying capacity.
- History: The Twin I-Beam suspension was first introduced in 1965 and was a hallmark of Ford's trucks for decades. A four-wheel-drive version, called the Twin Traction Beam, was also developed and used in 4x4 models.
When did Ford start using twin I-beam?
1965
Although the fourth-generation truck makes its debut in 1961 with a traditional solid-axle suspension, it eventually receives Ford's vaunted twin-I-beam setup in 1965.
Why does Ford still use leaf springs?
Turns out, there are some very good reasons for that, because while leaf springs might be from the Bronze Age, it's the coil springs that have an Achilles heel: They can't handle a lot of weight. The key strength of leaf springs is, well, strength. They can take on a much higher total load without risking failure.
Is Ford cancelling the lightning?
Ford is reportedly considering canceling the F-150 Lightning, but the decision is not final. Production was paused due to an aluminum supply shortage, and ongoing EV losses have led Ford to evaluate the future of the electric truck. While production is temporarily halted, there is no official announcement of cancellation yet.
- Production is paused: The F-150 Lightning assembly line at the Rouge Electric Vehicle Center is currently on hold, and Ford will not say when it will restart.
- Supply chain issues: A fire at a key aluminum supplier's plant caused a shortage, and Ford is prioritizing its more profitable gas and hybrid F-150s.
- Financial losses: Ford's electric vehicle division has been losing a significant amount of money, and the F-150 Lightning has been a major contributor to these losses.
- Uncertain future: The Wall Street Journal reports that Ford executives are in active discussions about ending the truck's production.
- Potential replacements: If production were to end, the F-150 Lightning might be replaced by a new vehicle built on the Universal Electric Vehicle (UEV) platform, according to MotorTrend.
