Your Legal Fuel Tank Source. ™

Transcription

Your Legal Fuel Tank Source. ™
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 1 of 22
THANK YOU FOR PURCHASING A TRANSFER FLOW, INC. MAXFLO-TFI FUEL
SYSTEM FOR YOUR 1999-2015 FORD SUPER DUTY DIESEL OR YOUR 1999-2004
FORD SUPER DUTY FUEL INJECTED VEHICLE WITH NON-CALIFORNIA
EMISSIONS. THIS SYSTEM IS NOT INTENDED FOR USE ON ANY GAS VEHICLE
THAT IS CERTIFIED TO CALIFORNIA EMISSIONS.
TRANSFER FLOW FUEL SYSTEMS AND PARTS ARE INTENDED TO BE USED IN
CONJUNCTION WITH ORIGINAL MANUFACTURER’S EQUIPMENT OR
TRANSFER FLOW SYSTEMS AND COMPONENTS.
OUR SYSTEMS AND COMPONENTS ARE NOT INTENDED TO BE USED IN
CONJUNCTION WITH OTHER AFTER-MARKET SYSTEMS. ATTEMPTING TO
USE OUR PRODUCTS INAPPROPRIATELY MAY LEAD TO MALFUNCTION AND
VOIDS THE WARRANTY. IN AN EFFORT TO ENSURE THAT YOUR TRANSFER
FLOW PRODUCTS PERFORM APPROPRIATELY FOR MANY YEARS TO COME,
WE ASK THAT YOU FOLLOW THESE GUIDELINES.
CAUTION: DO NOT HAVE ANY OPEN FLAME OR HEAT SOURCE CLOSE TO THE
INSTALLATION AREA.
PLEASE READ THE FOLLOWING PROCEDURES CAREFULLY BEFORE
STARTING THE INSTALLATION.
CAUTION: DO NOT OVER FILL.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 2 of 22
Section 1: Preparing the Vehicle
1. Key the ignition ON and take note of the fuel gauge. Mark the level that the gauge is
displaying in one of the illustrations below.
Use this diagram as a sketch pad. Draw the needle on the gauge as it appears in the truck.
2. Key the ignition off.
3. Disconnect the battery.
4. Empty the bed of any movable objects.
5. Extinguish any heat sources in the area.
6. You will have one of the following different foot positions for mounting.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
•
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 3 of 22
Feet are on the side for 30gallon and 50gallon aluminum diamond plate toolbox tanks, also
50 gallon and 98 gallon steel cross the bed tanks.
Feet on the side of
the tank
•
Feet are on the front and back sides of 75 gallon cross the bed tanks and 40 gallon steel
toolbox tanks.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
•
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 4 of 22
Feet for 50 gallon and 98 gallon aluminum diamond plate cross the bed tanks are on the sides
of the tanks and have 4 holes in each side. Only 4 of the 8 holes need bolts in them, 2 bolts
per side. Try to use the 2 holes that are as far apart as possible.
Section 2: Pre-position the Tank in the Bed of the Truck
7. Place the tank in the bed of the truck. The tank should be spaced about 1” away from the
head gate and centered from side to side. If you are installing a toolbox tank make sure there
is ample room to open the lid. In all cases the fill opening should be on the driver’s side.
8. Mark the mounting holes with a Sharpie®. If you cannot reach the mounting tabs near the
cab, attach a Sharpie® to a long stick with some electrical tape.
9. Remove the tank from the mounting area.
10. Measure the mounting hole locations using the head gate and bed corrugations as reference
lines.
11. Crawl under the truck.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 5 of 22
12. Measure and mark the bed mounting holes on the bottom side of the bed. Use the head gate
and bed corrugations for reference.
Head Gate
Hat Sections
Tail Gate
Corrugations
Front of Vehicle
This cutaway drawing shows the head gate and bed corrugations.
13. Look at the marks you have created and make sure that a 1/2” bolt with large shims will fit in
the area you have marked. It is OK to drill through the hat section of the bed, but you don’t
want to be drilling through the tall edge of the hat section. Make sure that your drilled hole
will pierce through the flat area of the hat section.
14. Move any wires, hoses or obstructions that may be scarred by a drill bit (you will be drilling
from the top down).
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 6 of 22
15. Double check your measurements and move the tank if needed. If you move the tank you
will need to remark the holes on the underside and double check your measurements once
again.
16. Get ready to start drilling (you will be drilling from the top down.)
Section 3: Mount the Tank
17. Drill pilot holes with a long 1/8” drill bit. Did the pilot hole come through the bottom where
you expected?
18. Drill two 1/8” pilot holes for the hoses and wiring harness in the box side panel. These holes
will be enlarged with a hole-saw later. Place the holes in the side of the bed about 2” up
from the bed floor. The hole locations relative to the head gate will be different depending
on the model year of the vehicle. Place the holes about 3” apart, center to center. Before
drilling the pilot holes make sure you are not drilling into anything valuable such as the
outside of the bed, wiring, hoses or other brackets. Do not drill these holes in the head
gate.
(2) 1 ¼”
holes in box
side panel
Front of the truck.
19. Enlarge the holes for the hoses and wiring harness with a 1 ¼” hole-saw. Insert the provided
rubber grommets into each hole.
20. Enlarge the tank mounting holes with a 9/16” drill.
21. Attach the (3) sticky back foam strips to the bottom of the tank or truck bed. Position one
strip next to each mounting angle and one strip under the middle of the tank. These strips
will prevent the tank from rubbing directly on the bed.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 7 of 22
NOTE: If the bed of the truck has a sprayed on or plastic bed liner the rubber strips may not be
required.
22. Place the tank in its final position.
This is a 75 gallon
cross the bed tank
your tank may be
different than
pictured.
23. Place shims under the mounting brackets to prevent the corrugations from collapsing. See
drawing below.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 8 of 22
24. Insert the 1/2” carriage head bolts through the mounting brackets and bed.
25. Secure fasteners with washers and nuts and torque the nuts. Refer to Instruction Sheet #484
for proper torque specifications.
Double check your work: at this point the tank should be secured in the bed and all of the
hardware should be properly torqued. The pump and module should be attached to the tank and
grommets should be installed in the two holes for the wire harness and hoses. If you are
installing a toolbox, make sure the lid functions without rubbing on the bedrails.
SECTION 4: PLUMBING THE SYSTEM
Vent Hose
MAXFLO-TFI
Module
Fuel Transfer
Hose
Rollover Vent Valve
Fuel Pump
Fuel Filter
Components underneath cover box on top of cross the bed tank.
26. Make sure the fuel transfer hose is hooked up to the TFI fuel pump.
27. Route both of the hoses though one of the grommets in the pickup bed.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 9 of 22
28. Crawl under the truck.
29. SINGLE TEE INSTALLATION ON 1999-2015 MODEL VEHICLES:
30. Find the OEM vent hose that runs from the fillneck to the OEM tank. Locate the end of the
hose where it transitions to the metal vent tube on the fillneck. Cut the rubber hose at a spot
about 2” inboard of the OEM hose clamp. Remove an additional ½” of hose from the rubber
hose that is still attached to the OEM fuel tank. 1999-2007 Model Vehicles: If your truck is
a short bed, you will need to detach the vent hose from the OEM tank to make this step
easier.
NOTE: On 2011 and new model years there is a DEF (Diesel Exhaust Fluid) tank located
behind the OEM fuel tank. There are two fillnecks located in the fill door area. Do not install
the tee into the DEF tank fillneck.
Main tank fillneck
Install single tee to
this fillneck
DEF tank fillneck
Do not make any
modifications to this
fillneck
Front of the truck.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 10 of 22
31. Install the provided single tee into the vent hose. The 3/8” nipple of the tee needs to point
towards the outside of the truck and rotated in an upwards fashion. The tee can be angled up
a little bit if it will help with your install. Do not let the tee point downhill.
32. Install the provided hose clamps onto the large ends of the single tee. Refer to Instruction
Sheet #484 for proper torque specifications.
33. Find the fuel transfer hose that is attached to the TFI fuel pump. Route this hose to the single
tee that you have just installed and trim it to length. Make sure that the hose does not rub on
anything hot or sharp or interfere with other vehicle systems such as the e-brake cable, fill
hose, electrical harness or TFI tank mounting bolts. 1999-2007 Model Vehicles: Again, if
you are working on a short bed truck you may want to complete this step before you
reattach the OEM vent hose to the OEM tank.
34. Attach the fuel transfer hose to the Single Tee with the provided hose clamp. Refer to
Instruction Sheet #484 for proper torque specifications.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Aux Supply
Line
Page 11 of 22
OEM Vent
Hose
Front of the vehicle
Single Tee
This photo shows the single tee when it is completely installed on a long bed truck.
35. Find the TFI emissions hose that should be attached to the Rollover Valve (ROV) on the top
of the TFI tank. Route this hose to a location under the truck where the end can be pointing
down and secure the hose with a zip tie. Do not allow this hose to kink or get pinched shut
by the zip tie. The ROV helps vent the tank when you are filling it by venting the top of the
tank to the atmosphere or through an emissions canister. Trim the vent hose to length if
necessary.
CAUTION: FOR FUEL INJECTED GAS VEHICLES, FOLLOW INSTRUCTIONS
IN THE CANISTER ASSEMBLY KIT REGARDING CONNECTION OF THIS ROV
HOSE TO THE CANISTER. IF THIS HOSE IS NOT CONNECTED TO THE
CANISTER, THE CHECK ENGINE LIGHT MAY ILLUMINATE ON YOUR
INSTRUMENT PANEL.
36. Double check your work: at this point all the hose clamps should be tight, and all of the
hoses should be routed away from hot or sharp objects and free from kinks. 1999-2007
Model Vehicles: If you are working on a short bed, make sure the OEM vent hose is reattached to the OEM tank.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 12 of 22
Section 5: Wiring the System
37. Find the TFI wire harness.
38. Mount the MaxFlo-TFI module to the tank. If you have a MaxFlo-TFI Toolbox, the module
will mount inside of the tool box with supplied screws and nuts, but you will have to remove
the cover box inside of the toolbox to access the screws.
39. If you are installing a cross bed fuel tank, remove the cover box on top of the tank that is held
down with Velcro. The module will mount to the single stud, and be secured with a nut. For
diamond plate fuel tanks the module is held on with adhesive backed Velcro.
MAXFLO-TFI
Module
Mount module to
tank stud and
secure with nut
40. Connect the Fuel Pump, Power and 10 pin connector on the wiring harness to the MaxFloTFI module. The 10 pin connector needs the provided rectangle gasket installed before
installing onto module. The wiring connectors should plug together with a snap but you need
to make sure that the tongue and groove on each connector is properly lined up. These
connectors are designed to only work one way.
•
The 22AWG grey wire is not used unless the optional switch/light kit have been
purchased (See instruction sheet if purchased). If the light/switch kit has not been
purchased insert grey wire back into convolute.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 13 of 22
•
The 20AWG black with ring terminal and the 22AWG violet with spade connector
are not used unless the optional switch/aux gauge kit, (When available).
•
See wire diagram on last page of installation instructions.
MAXFLO-TFI Module
41. Route the wiring harness through the unused grommet.
42. Crawl under the truck to the frame-rail area near the fill hose and single tee.
43. Find the OEM wiring harness that runs outside of the frame rail. In the section between the
rear cab mounts peel back about 5” of the plastic cover from the wire harness to expose the
wires inside.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 14 of 22
44. Pay attention to the next few steps; they are critical to making sure the system works
correctly!
45. Find the OEM sending unit wire by comparing the wire colors on this chart:
Ford Sending Unit Wire Color Chart
Year
Sending Unit Signal
Sending Unit Ground
1999
2000
2001
2002
2003
Yellow wire with White
Stripe
2004
Black wire with Orange
Stripe
Not Black wire with Pink
Stripe!
2005
2006
2007
2008
2009
2010
2011
Yellow wire with Purple
Stripe
Green wire with Blue Stripe
2012
2013
2014
2015
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 15 of 22
46. Cut the sending unit wire.
47. Verify that you have cut the correct wire by performing this test:
•
Hook up the vehicle’s battery temporarily
•
Key the ignition ON.
•
Watch the fuel gauge. If the gauge reads past full or past empty (more than the regular
range of the fuel gauge) then you know that you have cut the correct wire. If the gauge
stays at the same level that you marked in the gauge schematic, you may have cut the
wrong wire. If you are working on a 2001-present Super Duty, you may have to wait
several minutes for the gauge to react. If you are working on a 1999-2001 vehicle and
the gauge does not react within 5 minutes of the ignition being switched ON, you have cut
the wrong wire. Repair the mistaken wire and cut the correct one.
•
Key the ignition off.
•
Disconnect the battery.
48. Find the wire that you cut, and strip 3/16” of insulation off of each end. Label the end of the
wire that heads to the front of the truck as “GAUGE”, label the end of the wire that heads to
the OEM fuel tank as “SENDER”.
49. Locate the TFI wire harness and route the Yellow, White, Green, and Black with White
Stripe wires to the area that you are working. Make sure the wire harness is not rubbing on
any sharp objects or interfering with the vehicle’s other systems such as, e-brake cable, fill
and vent hoses or TFI tank mounting bolts.
50. Connect the TFI YELLOW wire to the wire you have labeled “GAUGE” in step #48. Make
this connection with the 18-22 gauge butt connector and insulate the connection with the
supplied heat shrink.
51. Connect the TFI WHITE wire to the wire you have labeled “SENDER” in step #48. Make
this connection with the 18-22 gauge butt connector and insulate the connection with the
supplied heat shrink.
52. Cut the OEM sending unit ground wire.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 16 of 22
53. Find the wire that you cut, and strip 3/16” of insulation off of each end. Label the end of the
wire that heads to the front of the truck as “GAUGE”, label the end of the wire that heads to
the OEM fuel tank as “SENDER”.
54. Find the TFI BLACK W/ WHITE STRIPE wire. Connect the TFI Black w/ White Stripe wire
to the sending unit side of the ground wire that you cut in step #53. Make this connection
with the 18-22 gauge butt connector and insulate the connection with the supplied heat
shrink.
55. Find the TFI GREEN wire. Connect the TFI GREEN wire to the gauge side of the ground
wire that you cut in step #523. Make this connection with the 18-22 gauge butt connector and
insulate the connection with the supplied heat shrink.
56. Replace the plastic covering over the OEM harness and secure the TFI harness alongside of
the OEM harness. Wrap the connection of the two harnesses with electrical tape.
57. Route the TFI harness toward the front of the truck. Secure it inside of the driver’s frame rail
to the OEM harness with zip ties. Do not attach the harness to the fuel or brakes lines.
58. Crawl under the truck to an area underneath the cab near the driver’s frame rail.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 17 of 22
Section 6: Electrical Power Connection
59. Route the end of the harness with the red power wire and black with white stripe ground wire
towards the fuse box in the cab of the truck.
•
Either drill a 1-1/4” diameter hole into the firewall, and install a TFI 1-1/2” rubber
grommet, or use an existing OEM rubber grommet, to route the wire harness from the
engine compartment into the cab. Prior to drilling the hole, make sure that the hole will not
enter or interfere with any other components on the vehicle, such as the floor mat. Insert
the supplied 1-1/2” rubber grommet and route the power wire and convolute through the
grommet and into the cab.
60. The white six-pin connector is for the switch/light kit or switch/gauge kit, if the optional
upgrade has been purchased please reference those installation instructions. Due make sure
connector is left inside cab.
61. Connect the red power wire to the vehicle’s fuse box.
•
1999-2007 Model Vehicles the fuse box is located under the steering column.
•
2008-2015 Model Vehicles the fuse box is located in the passenger kick panel.
• Reconnect the vehicle’s battery.
•
Find a keyed-on fuse, see next page. Remove the fuse from the fuse box. Slip the
legs of the fuse into the Tap-a-Fuse. The ATM fuse tap will fit the small mini
fuses.
Supplied 5
Amp Fuse
OEM Fuse
Tap-a-Fuse
Figure 1: Tap-a-Fuse with fuses installed
SEE FUSE CHART ON NEXT PAGE
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
July 02, 2014
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
IS#836
Page 18 of 22
Ford Fuse Locations
Year
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
Location of Fuse Panel
Fuse ID Number
Fuse panel is located under the
steering column, behind a
removable panel.
Fuse #33
Fuse panel is located behind the
passenger side kick panel.
Fuse #34
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 19 of 22
• Insert the Tap-a-Fuse into the fuse box. Make sure that the leg of the fuse furthest
from the wire sticking out the side is inserted into the hot side of the fuse
connection. Verify that power is supplied to the inline fuse adapter when the
vehicle’s ignition is keyed ON and is disconnected when the ignition is OFF.
Tap-a-Fuse
Insert this side into the
hot side of the fuse
62. Secure the wire harness with zip ties. Make sure that the harness is not hanging loose or
routed so that the wire can get tangled in the e-brake mechanism or the drivers feet.
63. Replace the fuse panel cover.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 20 of 22
ELECTRICAL GROUND CONNECTION:
64. At the forward end of the MaxFlo-TFI wire harness you will find a black with white stripe
ground wire.
NOTE: This ground wire must be attached to the vehicle or the MaxFloTFI system will not operate properly.
This ground wire must be attached to a suitable ground. Look under the dashboard for a
ground lug that has OEM grounds attached. Ground this wire to the OEM ground using
the supplied eyelet. If no OEM ground is available under the dash you will need to route
the ground wire back through the floor grommet and ground it to the frame. Follow
these steps:
•
Drill a 5/32” diameter hole in the inside of the driver’s side frame rail. Clean the
area around the hole to bare metal. Obtain the #10 eyelet and #10 star washer
from the TFI kit. Route the black wire in the TFI harness to the hole location on
the frame. Secure the wire using a #10 eyelet, #10 star washer, and a #10 sheet
metal screw that is provided in the install kit to ground the system. Coat the
ground connection with dielectric grease or Kopr-shield.
65. Double check your work: at this point the wiring should be complete: the pump and
module are plugged in, the harness is routed along the frame and secured with zip ties, the
sending unit connections have been made and tested, the harness wrappings are taped
closed, the ground wires are secured and the red power wire is tapped into the fuse box.
66. Reconnect the battery.
67. Fill the Auxiliary tank up with fuel.
68. Affix the Door Post Label and Tire & Loading Labels. If you cannot find your fuel tank on
the Instruction Sheet #642 weight list, then disregard the tire and loading label.
Tire & Loading Label
This kit comes with a new Tire & Loading Label. Update the new label and place it directly over the old label.
Ford Vehicles Only
Transfer Flow, Inc.
1444 Fortress Street
Chico, CA 95973
Phone: (530) 893-5209
Sales/Tech: 1-800-442-0056
Fax: (530) 893-0204
Website: www.transferflow.com
Aftermarket & OEM Fuel Tanks
Toolbox & Fuel Tank Combos
In-bed Fuel Tanks
Refueling Tanks
Retrofit Fillneck Kits
Auxiliary Fuel Systems
Replacement Fuel Systems
Your Legal Fuel Tank Source. ™
July 02, 2014
IS#836
Page 21 of 22
69. Perform the MAXFLO-TFI test and verification procedure, see IS #833.
Door Post Label
The Silver Label should be affixed to the door post
70. Congratulations on a successful installation. Please refer to the user’s guide that TFI has
supplied if you have any questions on the operation of this system.
Tool List
Sharpie
Hose cutters
Long 1/8” drill bit
Electrical tape
5/32” drill bit
Sand paper
½” drill bit
Heat gun
9/16” drill bit
Kopr-Shield coating
7/8” drill bit
0-50 ft-lb torque wrench
1 ¼” hole saw
Ratchet
Diagonal cutters
Extensions
Wire strippers
8mm socket
7mm socket
¾” socket
Ford Vehicles Only
March 12, 2014
IS#836
Your Legal Fuel Tank Source. ™
Ford Vehicles Only
Page 22 of 22