Curtis73 (Forum Supporter) said:
Well, F150s in that year range are rated to tow anywhere from 10k to 13k, so I wouldn't worry about towing 4k.
The only real reason I might lean toward an F250 is because things are just beefier. Ball joints, tie rod ends, bushings, brakes, shocks, bearings, axles, etc. My F150 needed maintenance much like a car - brake pads every 16 months or so, chassis and suspension parts every 60k or so. My F250 I owned from 60k miles until 150k miles, and I did brake pads once. I never did any chassis parts, although when I sold it one rear shock was leaking a bit. It looked OEM.
My F150 was as reliable as Taurus. Drove a bit more like a car, needed replacement parts like a car. My F250 was as reliable as a chunk of Oak. I knew that as long as it passed PA inspection, it was a no-brainer. I could count on it to not need parts for years.
The downside is potentially larger turning radius, stiffer ride (although they're getting so good with this), potentially higher registration cost. In PA, if I have a dually, I can register it as a Class 1 truck (like a Ranger), but then I'm technically required to stay under a certain GVW despite what the truck's doorjamb says. Some states, you pay based on the GVWR.
I rarely tow more than 6000 these days, so my Express 1500 is more than enough, but if GM had made a true 2500 Express with AWD, I'd be driving it now. In truth, GM did make a one-year 2500 AWD, but it was a total sham. They added a leaf to the rear springs and put a 2500 badge on it. The front chassis was strictly 1500 parts bin.
Edit to add: Check with your insurance/state. Insurance might see an F250 as implied heavy-duty/towing use and it might be more expensive.
Registration in PA seems to vary wildly. My 1995 2500 Cummins (8800 GVWR) was titled as Class 2. Why? I have no idea... because former farm truck? All I know is annual registration was $154/year at the time (sold in 2013). I think it's now around $200/year. I don't know if that had any affect on insurance. Vans are different. It seems most full-size passenger vans get titled as station wagons, regardless of size/weight. My E350 extended hi-roof weighs every bit as much as the Cummins but annual registration is the same as a passenger car. Go figure.
For trucks, I also lean towards the "bigger is better" rule but I've also never been shy of overkill when it comes to tools. And a truck is a tool. One reason I bought the Cummins is for hauling heavy stuff in the bed. Fire wood, mulch, etc. Three yards of mulch (~3000 lbs) in the bed just made the Cummins ride nice... otherwise it did not care. Of course, this is also why any truck I buy will have an 8' bed. Anything shorter is pointless. Granted, the truck was usually a secondary vehicle and rarely daily driven. I may have different opinions if I needed to drive it every day.