The new 2010 Ford Shelby GT500 delivers the most power and refinement ever for a Ford SVT-tuned performance Mustang – and a few surprises, too.

“In addition to the numerous performance and refinement improvements inside and out, the 2010 Shelby GT500 is an estimated 2 miles per gallon more fuel efficient on the highway.”

Ford’s Special Vehicle Team used the gains made on the 40th anniversary edition Shelby GT500KR “King of the Road” Mustangs as the performance starting point and built from there. The design team, with a nod to the original Shelby Cobras from the 1960s, takes those design cues even further with nuanced improvements in both the coupe and convertible, each of which boasts a more-refined interior.

The 2010 Shelby GT500 is powered by a supercharged and intercooled 5.4-liter dual overhead cam V-8 engine expected to produce 540 horsepower and 510 foot-pounds of torque. The redline is 6,250 rpm. The car’s aluminum power dome hood not only adds to the Shelby’s appearance, it helps cool the engine through a hood extractor.

The Shelby’s open-element air induction system features a conical air filter instead of a flat-panel closed system to reduce air restriction. This approach allows more air to be pumped through the engine, producing more power and increasing the engine’s efficiency.

A cold-air intake feeds the coolest air possible directly into the air box, helping further increase horsepower. The intake necessitated moving the Cobra snake badge to the other side of the grille to enable maximum airflow.

The twin-disc clutch on the six-speed manual transmission has been significantly upgraded, improving drivability and NVH. The discs on the 2010 Shelby GT500 are larger – 250 mm in diameter compared with 215 mm in diameter on the outgoing model – and made of copper and fiberglass to make them more robust.

A unique component of the twin-disc system is the control of the intermediate disc. Rather than floating, it instead has six straps that control the engagement of the clutch, improving drivability.

The 2010 Shelby GT500 offers customers improved straight-line acceleration, plus fuel savings when cruising on the highway in the top gears. Gears 1-4 remain the same, but fifth gear changes from .80 to .74 while sixth gear goes from .63 to .50, meaning that the 2010 Shelby GT500 will turn lower engine RPMs in those gears and deliver improved fuel efficiency. The new final drive ratio, from 3.31 to 3.55, enables the improved acceleration in lower gears while complementing the revised fifth and sixth gear ratios.

The Shelby’s distinct sounds will be apparent as always, though with new refinements, thanks to the work of the Noise, Vibration and Harshness (NVH) team. A patented resonator placed between the air filter and engine throttle body helps keep unwanted noise in check.

“You still hear the supercharger but not so that it’s intrusive,” said Kerry Baldori, chief functional engineer for SVT. “It’s the same with the exhaust. You want people to know you’re driving something special, but you don’t want an exhaust note that overpowers the whole interior.

“We spent a lot of time getting the right sound quality out of the exhaust so you get that nice, crisp Shelby sound outside and a pleasant sound inside the cabin. It’s a nice balance; one isn’t overpowering the other.”

Driving dynamics also are improved, thanks to SVT’s signature chassis tuning as well as new 19-inch Goodyear F1 Supercar tires and forged aluminum wheels on the 2010 Shelby GT500 coupe and 18s on the convertible.

Spring and dampers have been optimized for better roll control, giving customers more confidence when braking, accelerating or turning. The new chassis tuning takes its philosophy from the KR program, with a greater emphasis placed on primary body control.

The team also stiffened the steering shaft.

“All our changes were about making the car to respond as fast and as predictable as possible,” Hameedi said. “The 2010 Shelby GT500 conveys an athletic, confident feel. The shifter, clutch pedal, brake-pedal efforts and overall steering efforts are easier now. We wanted to make sure we had a nice, crisp short-throw shifter that was easy to go from gear to gear.”

The Goodyear F1 Supercar 19-inch tires have been upgraded, too. SVT members developed a “recipe” for the attributes and characteristics they wanted in the tire, which Goodyear’s team of engineers, designers and manufacturers brought to life. The result is better grip, better handling and better NVH properties, leading to a better customer experience.

The wheels themselves complement the high-performance nature of the 2010 Shelby GT500. The 19-inch wheels are forged aluminum wheels milled on both sides. The extra machining process creates “blade” spokes with very thin, yet strong, cross-sections. The spokes have a specific curve from the rim to the hub, not only for strength, but also to accentuate the offset and width of the tires.

The 2010 Shelby GT500 features AdvanceTrac, Ford’s stability control system with several options for performance. The default “on” mode accommodates every-day driving, and a Sport mode delivers for those wanting to put the Shelby GT500 through its paces on the track. The system also can be turned completely off, although the anti-lock brake system and other active safety systems remain in place. Standard safety equipment includes: dual stage front air bags, side-impact air bags and Ford’s Personal Safety System.

Numerous aerodynamic upgrades, including a redesigned splitter, were made to the front end of the 2010 Shelby GT500.

“We worked hard to get as much downforce with as little drag as possible,” Baldori said. “We worked to seal off the air that comes in the front so it can’t go underneath the car. We spent a lot time sealing components such as the radiator and intercoolor to get rid of all the leak paths.

“The result of this evolution of aerodynamics is we’ve increased downforce, reduced drag and improved the overall efficiency of the 2010 Shelby GT500.”