Aftermarket & OEM Fuel Tanks 1444 Fortress Street Toolbox ......Retrofit Fillneck Kits Auxiliary...
Transcript of Aftermarket & OEM Fuel Tanks 1444 Fortress Street Toolbox ......Retrofit Fillneck Kits Auxiliary...
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December 4, 2015 IS# 803 Page 1 of 13
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. ™
THANK YOU FOR PURCHASING A TRANSFER FLOW, INC. 60 GALLON
REPLACEMENT FUEL SYSTEM FOR YOUR 2011-2016 GM 2500HD AND 3500HD
2X4 AND 4X4 CREW CAB SHORT BOX DIESEL PICKUP. PLEASE READ THE
FOLLOWING PROCEDURES CAREFULLY BEFORE STARTING THE
INSTALLATION.
CAUTION: DO NOT HAVE ANY OPEN FLAME OR HEAT SOURCE CLOSE TO
THE INSTALLATION AREA.
CAUTION: THIS TANK MUST NOT BE INSTALLED ON A 1500 HD PICKUP. THIS
TANK FITS 2500 HD AND 3500 HD PICKUPS ONLY.
TANK REMOVAL:
1. For safety reasons, disconnect the battery cables.
2. Using a 5/16” socket, remove the OEM hose clamp from the 5/8” I.D. vent hose. Use a
5/16" socket to remove the OEM fill hose clamp from the OEM tank, and remove the hose
from tank. Remove the OEM vent hose from the OEM fill neck.
3. Place a hydraulic jack underneath the 36-gallon OEM midship fuel tank. Raise the jack until
contact with the tank is made.
4. After making sure the tank is well supported, remove the OEM bolts that secure the OEM
mounting straps using a 15mm deep socket and a 10” extension.
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December 4, 2015 IS# 803 Page 2 of 13
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. ™
5. Disconnect the fuel supply and return hoses from the OEM fuel lines at the front of the OEM
plastic fuel tank.
CAUTION: FUEL WILL BE UNDER PRESSURE AND WILL LEAK FROM
THESE DISCONNECTED FUEL LINES. KEEP THE OPEN ENDS AWAY FROM
ANY HEAT SOURCE, AND PLACE A DRIP PAN BENEATH THEM.
6. Remove the OEM tank straps from the vehicle and discard.
7. Remove the electrical harness from the retainer clip on the front OEM crossmember.
Disconnect the electrical connector from the OEM sender connector.
8. Completely remove the stock 36-gallon OEM midship fuel tank out from under the vehicle.
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December 4, 2015 IS# 803 Page 3 of 13
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. ™
VEHICLE PREPARATIONS:
9. Locate the bracket in front of the OEM tank location next to the fuel lines. This bracket will
need to be removed before the TFI tank can be installed in the vehicle. Using a Saws-all or
other saw remove the bracket at the square base, leave the square base attached to the frame
rail. See picture below for more details.
OEM Fuel
Lines
OEM Frame
Rail
OEM
Bracket
OEM
Tank
Cut the Bracket
off at the White
Dashed line
OEM Frame
Rail
OEM Bracket
cut down
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December 4, 2015 IS# 803 Page 4 of 13
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. ™
TFI TANK INSTALLATION:
10. Install the upper front strap into the front hanger bracket along with the front upper strap key,
use one of the OEM bolts to hold the strap in position while the tank is being raised into
position.
11. Install the rear upper strap key into the rear hanger bracket.
OEM Bolt in
OEM Bolt
Position
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December 4, 2015 IS# 803 Page 5 of 13
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. ™
12. Disconnect OEM supply and return hoses from the OEM sender.
13. Using a flat blade screwdriver and hammer, rotate and remove the cam ring that secures the
OEM sending unit to the OEM 36 gallon plastic tank. Use an air nozzle to remove any dirt
from the lip seal and cam ring connection. Remove the OEM sender, OEM sender o-ring and
OEM fuel hoses from the tank.
CAUTION: THE OEM SENDER AND RESERVOIR WILL BE FULL OF FUEL.
USE A DEEP OIL PAN TO CAPTURE THE FUEL.
14. Carefully remove the OEM sending unit float wire by pushing up on the wire until it comes
free from the clip. Remove the OEM sending unit float wire and discard. See Photo.
Disconnect
from OEM
Sender
Disconnect
from OEM
Sender
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December 4, 2015 IS# 803 Page 6 of 13
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. ™
15. Align the TFI sender wire onto the OEM sending unit and press into place.
16. Attach one lead of an ohm meter to the sender wire male pin. Attach the other lead of the
ohm meter to the ground wire male pin. See the OEM sender electrical connector details on
the isometric print. With the float at the bottom stop, as if the tank were empty, the meter
should read between 246-256 ohms. Rotate the float wire to the top stop, as if the tank were
full, and test to verify that the resistance is between 34-43 ohms
17. Remove the TFI compression ring, the TFI O-ring, and the blank cover plate from the TFI
tank using a 7/16” socket. Place the TFI compression ring over the OEM draw and return
tubes on the top of the OEM sender cover plate.
Pull in the
indicated
direction to
release OEM
float wire.
Pull in the
indicated
direction to
release OEM
float wire.
Sender Signal
Sender Ground
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December 4, 2015 IS# 803 Page 7 of 13
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. ™
18. After confirming that the surface of the OEM sender gasket will rest on is clean and free of
dirt or other debris, place the OEM lip seal gasket (or TFI O-ring) into the TFI fuel tank
sender opening. Carefully position the OEM sender into the TFI tank, orienting the OEM
sender so the float arm is parallel to the long axis of the tank and rotating toward the front of
the fuel tank. The flange on the OEM sender will locate the assembly in the proper position,
with the supply and return tubes facing towards the drive shaft side of the vehicle.
19. Secure the compression ring to the bolt ring with the ¼”-20 flange nuts. The
compression ring has a specific hole pattern that will only go the tank one way. Refer to
Instruction Sheet #484 for proper torque specifications.
CAUTION: DO NOT OVER TIGHTEN THE NUTS OR PERMANENT DAMAGE TO
THE STUDS MAY OCCUR.
20. Confirm that the cam ring hole in the TFI tank is clean and free of paint or score marks. If
paint is on the inside side surface of the opening, use either a fine grit sand paper or solvent,
and remove the paint. After applying a light coat of oil to the cam rollover valve o-ring,
install the rollover vent valve assembly into the cam ring hole on the TFI tank. Rotate the
valve clockwise so the port and 4” long hose are pointing towards the driver’s side frame rail.
21. Using a 5/16” Allen wrench, remove the (2) 3/8” MPT steel plugs from the 3/8” weld flanges
on the side of the fuel tank. Apply Permatex sealant to the male threads of the 3/8” MPT x
1/2” barb brass elbows. Using a 15mm” box open-end wrench, secure the elbows into the
tank so they face each other. Using a 7mm socket, install the ½” I.D. long hose and #6 gear
clamps onto both 3/8” MPT x 1/2” barb brass elbows. Orient the gear clamps so their screw
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December 4, 2015 IS# 803 Page 8 of 13
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. ™
heads are facing the bottom of the tank. Refer to Instruction Sheet #484 for proper torque
specifications.
22. Reattach the ohm meter leads as before. With the tank resting on level ground, positioned as
if it were in the vehicle, the resistance reading should again be between 246-256 ohms.
Rotate the tank upside down simulating the float arm in the tank full position. The ohm
meter should read between 34-43 ohms.
23. Place plastic caps over the 1/2” and 3/8” supply & return fittings. Also use a vise grip to seal
off the 7/16” I.D. rollover vent hose. The tank must now be pressure tested. After all the
openings are sealed, punch a small hole in the fillneck red plastic cap and pressurize the tank
to a maximum of 5 psi. Using a soapy water solution, thoroughly check for leaks around all
openings. If any are present, reseal the affected area and retest. Remove all of the plastic
caps and the vise grip after testing is complete. Also remove the 1/2” I.D. hose from the both
3/8” MPT x 1/2” barb brass elbows.
24. The fuel line extension has two different size 90 degree fittings on the ½” hose. The fitting
with the white clip will attach to the ½” supply line in step #26. The fitting with fitting with
the black clip attaches to the sending unit.
TFI fuel line extension
This end of the
fuel line extension
attaches to the
OEM sending unit
This end of the extension
attaches to the
OEM fuel lines
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December 4, 2015 IS# 803 Page 9 of 13
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. ™
25. Connect the TFI 1/2” supply and 3/8” return fuel hoses to the appropriate OEM metal tubes
at the crossmember that you previously removed. Route the TFI 1/2” supply and 3/8” return
fuel hoses towards the back of the vehicle along the top of the frame rail.
26. Position the TFI fuel tank assembly underneath the vehicle in the midship mounting location.
The fill tube must be facing toward the driver’s side frame rail.
27. Slowly raise the fuel tank. While you are raising the fuel tank make sure that the front upper
strap is going into position correctly, the hole in the strap should line up with the OEM nut
clip that we removed the OEM bolt from earlier. The rear of the TFI tank has a centering pin
on top of the tank that will go into the hole in the rear crossmember.
28. Raise the TFI fuel tank to its final resting position. Care should be taken not to pinch the fuel
lines or the electrical harness as the tank is raised.
OEM Frame
Rail
TFI Fuel
Lines
OEM Metal
Fuel Lines
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December 4, 2015 IS# 803 Page 10 of 13
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. ™
29. Using a 7mm socket, connect the TFI 1/2” I.D. vent hose to the both 3/8” MPT x 1/2” barb
brass elbow with a #6 gear clamp. Using a 7mm socket and a 12-14” extension set the torque
of the gear clamp. Refer to Instruction Sheet #484 for proper torque specifications.
30. Route the TFI 1/2” and 3/8” fuel lines from the OEM frame rail to the OEM sender and
connect them to the appropriate fittings.
TFI 1/2” and
3/8” Fuel
Lines.
Outside of
Driver Side
Frame Rail
TFI 1/2” and
3/8” Fuel
Lines.
TFI Tank
OEM Vent
Line
3/8” MPT x 1/2” barb
brass elbow
3/8” MPT x 1/2” barb
brass elbow
TFI 1/2”
Hose
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December 4, 2015 IS# 803 Page 11 of 13
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. ™
31. Connect the electrical connector from the main harness to the OEM sending unit.
32. Loosely install the TFI lower rear strap (040-AG-10142) to the TFI upper rear strap key on
the drive shaft side using the provided 7/16”-14 x 1 ½” hex bolt, 7/16” flat washers and
7/16”-14 torque prevailing nut. Attention to the frame rail side is important to insure proper
fitment of the strap. Verify that the gap between the frame rail and strap is no more than ¾”
if you find that the gap is larger please use one of the supplied spacers found in your kit.
Secure the frame rail side of the TFI front lower strap to the OEM nut clip using the OEM
bolt that you removed earlier.
Large gap will
cause strap to
stress
Only use supplied
shim if needed. A
loose strap will cause
the tank to move.
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December 4, 2015 IS# 803 Page 12 of 13
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. ™
33. Proper foam compression will ensure you tank stays in place. The image above is an example
of proper compression of the foam and proper tension on the strap.
34. Loosely install the TFI lower front strap (040-AF-10142) to the TFI upper front strap key
using the provided 7/16”-14 x 1 1/2” hex bolt, 7/16” flat washers and 7/16”-14 torque
prevailing nut. Secure the other side of the TFI front lower strap to the OEM nut clip using
the OEM bolt that you removed earlier. You will need to line up the upper strap hole with the
lower strap hole before installing the OEM bolt.
35. Confirm that the tank straps are hanging straight down and there is at least 1 1/4” of
clearance between the tank, differential, and any part of the drive shaft. First, secure and
torque the 7/16”-14 nuts on the drive shaft side on both straps. After the inside fasteners are
secured, secure the OEM bolts to the frame. Refer to Instruction Sheet #484 for proper
torque specifications.
36. Connect the 1 1/2” fill hose to the fill tube on the TFI tank. After confirming there are no
kinks or twists in the OEM fill hose, secure it to the TFI 1 1/2” O.D. fill tube with the OEM
gear clamp. Refer to Instruction Sheet #484 for proper torque specifications.
37. Secure the vent hose to the OEM fill hose using the supplied 11” nylon ties. Make sure the
vent hose has a constant downward slope to the TFI tank. Secure the end of the hose to the
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December 4, 2015 IS# 803 Page 13 of 13
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. ™
OEM vent tube. This hose may need to be trimmed in order to prevent kinking. Secure with
OEM clamp. Refer to Instruction Sheet #484 for proper torque specifications.
38. Make sure all fuel and vent lines and electrical wires are not kinked or pinched, close to any
heat source, or in contact with any sharp edges. Confirm that the OEM fillneck has a
continuous downward slope from the fillneck to the fuel tank.
39. Reconnect the battery cables.
40. Fill the replacement tank with fuel. Start the engine and check for normal engine and fuel
gauge operation. If any problem is detected, shut off the engine and repair the connection.
41. The following are approximate gallon readings versus gauge position for the 60-gallon diesel
replacement system with replacement floatwire. Your system may vary depending on gauge
and sender tolerances
Tool List
Gauge Reading Gallons
Empty 8 gallons
1/4 15 gallons
1/2 22 gallons
3/4 31 gallons
Full 54 gallons
Total capacity: 60 gallons
15mm Socket Flat screwdriver 5/16” Allen Wrench
11/16” Socket Multi-Meter Torque Wrench
7/16” Socket 15mm Open End Wrench Hammer
7mm Socket 5/8” Open End Wrench Socket extensions
5/16” Socket