Deep Drive: 2009-2010 Roush Propane Ford F-250 and E-25 by Ed Piotrowski 
Performance-tuning company Roush now offers kits to convert certain Ford work vehicles, like this 2009 Ford F-250, to run on propane.
Though the need for speed is a focal point of Roush’s modus operandi, in a somewhat ironic twist, the company is looking to be known as a pioneer in the realm of alternative fuels. To that end, Roush is offering kits for Ford’s F-150, F-250 Super Duty, and E-250 commercial vans to convert them to run on propane, rather than gasoline.
Commercial fleets are Roush’s target customers for the conversions, and the up-fits can be done on-site by licensed installers, or at the company’s assembly plant in Livonia, Michigan.
Propane--the Fuel
Many of you are probably already familiar with propane, whether you use it in your own home, or watch the cartoon “King of the Hill.” Residential, commercial, and recreational use accounts for about 42.5 percent of U.S. propane consumption, according to the Propane Education and Research Council (PERC). Propane as an automotive fuel accounts for only about 3 percent.
Propane is essentially a by-product of the crude oil and natural gas refining process. It’s a colorless, odorless, and non-toxic gas, though it’s typically stored in liquid form. In this state, it is stable and can be easily transported. It also burns cleaner than gasoline and diesel. Propane is recognized as an approved alternative fuel in the Clean Air Act of 1990 and the National Energy Policy Acts of 1992 and 2005. PERC says that propane clears emissions hurdles set both by the U.S. Environmental Protection Agency (EPA), as well as the stricter guidelines set forth by the California Air Resources Board (CARB).
PERC officials say that propane currently supplies about 4 percent of the energy the U.S. uses. They claim that almost 90 percent of the U.S.’ supply comes from domestic refining, with most of the balance coming from Canada. They further add that the U.S. has the world’s largest capacity for propane storage.
Because propane is stored as a liquid, the refueling procedure is similar to that of a conventional gasoline or diesel vehicle, and it takes roughly the same amount of time as well.
Propane--the Roush F-150, F-250, and E-250
Roush first introduced propane kits for the 2004-2008-generation Ford F-150. In 2009, the same kits will be available for the 2009 F-250 Super Duty, as well as the 2010 E-250 commercial van. The kit is not yet compatible with the recently revamped 2009 F-150, though company officials hope to have it ready sometime in 2010.
The kit works only on trucks powered by Ford’s 5.4-liter V8 engine. With propane, officials claim no loss in power, so the trucks still produce 300 horsepower and 365 lb-ft of torque.
The propane-powered Roush trucks are refueled through the factory-supplied fuel door at pumps that look nearly identical to traditional gasoline dispensers. Installation of the Roush propane kit takes about 8-10 hours, either at the company’s factory or by a licensed installer. The kit includes a specific fuel tank, stainless steel fuel lines, billet aluminum fuel rails, and specific electronic programming.
Discounting any obvious add-on badges, aside from the propane tank behind the cab, there is little immediate difference between a propane truck and a conventional model.
Certain tax advantages exist for alternative fuel vehicles, such as those that run on propane. The Roush Propane Ford F-250 and E-250 are shown here.
Once the engine fires up, there again is very little difference between the propane powerplant and the standard gasoline one. That same feeling of familiarity extends to the driving experience. The exhaust note will be slightly different, but only to those well versed in the stock F-Series powertrain.
On the road, power is smooth and linear, both from a stop, and in highway passing and merging. There is nothing in the driving experience to indicate that you’re making any compromises in capability. You can basically read our reviews of the Ford F-150, F-Series Super Duty, and E-Series for all the details of how these heavy haulers perform. The propane models are that similar to their gasoline counterparts.
The Bottom Line
Of course, converting one of these trucks to propane from gasoline is not exactly cheap. The F-150 kit, according to company founder Jack Roush, runs about $8,800, with the F-250 and E-250 versions about $1,000 more than that. However, any conversion done is eligible for a federal tax credit--F-250 conversions are worth $4,500.
Propane fuel is also less expensive, especially if a fleet has its own pumps. PERC officials claim a propane-pump installation costs the same or less than one for gasoline. The fuel is eligible for a 50-cent per-gallon tax credit, as well.
Aside from the initial outlay for the conversion kit, probably the biggest drawback to using propane is that it is less efficient than gasoline. The “gas mileage” hit is about 20 percent.
CG Says
E85 ethanol hasn’t set the world on fire as an alternative fuel, so what chance does propane have? The fact that it’s already produced as part of the oil/gas refining process helps, as does the fact that most of the propane used in the U.S. comes from domestic sources.
Many commercial fleets, whom Roush is targeting for its kits, already have the capability of using propane as a vehicle fuel. A refueling infrastructure would need to be put in place, though, as there are only about 2,500 propane pumps accessible to the public (there are about 10,000 private ones). Tax credits for both the vehicles and the fuel is appealing, as is the fact that installing Roush’s kit results in a truck that drives no differently than its conventional gasoline counterpart.
The 2004-2008 Ford F-150 were the first vehicles for which Roush offered propane-fuel conversion kits.
It’s a good start, one that can be part of a multifaceted solution to weaning America off of foreign oil. If this application catches on, perhaps we will start seeing more propane-powered vehicles.
02.06.2009
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