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The added muscle was obtained with numerous changes to the top end. According to Kapp, new cylinder head castings feature re-shaped intake ports that provide more charge tumble and swirl, without giving up maximum airflow. The powder metal valve seats are re-angled, and the exhaust valve heads ranger are 1mm larger. Cam timing is "slightly more aggressive -- there''s more area under the curve," Kapp notes.Feeding the new heads is a revised intake manifold. The two-section (aluminum and plastic composite) manifold''s communication valve, which connected the primary and secondary plenums on the ''98 manifold, has been effectively left in the closed truck position for ''99. This change was key to unlocking the area under the two torque peaks (see graph), says Kapp.

The third doors in both automakers'' vehicles are similar expect for seat belt and handle placement. Mr. Baughman argues that bed Ford covers developed the concept of a 3-door extended cab and applied ranger for a patent that was issued in 1989. GM says it has used a similar door on its full-size G-vans since the 1960s. Mr. O''Neill says GM developed the third door for its extended cab pickup in a special 23-month crash program.DETROIT -- Nissan Motor Co. Ltd. Plans to start production of standard-size pickup trucks in this country by 2004 using U.S. made steel and many U.S. components.

And truck the newest U.S. transplant, Mercedes-Benz U.S. International Inc. (MBUSI), is gearing up to begin producing saleable AAV SUVs in January.Bill Taylor vice president of operations (and a former manufacturing executive at Toyota''s Canada plant), says MBUSI is right on schedule. The plant is 98%-complete, and the last of three production trials is being wrapped up. Ramp-up of regular production will be very slow, he says, but the Alabama plant should hit high-volume levels by mid-year. A second shift starts in September when the $35,000 vehicles are officially scheduled to go on sale.

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