March 6, 2017 IS# 791 Page 1 of 16 · March 6, 2017 IS# 791 Page 4 of 16 Transfer Flow, Inc. 1444...

March 6, 2017 IS# 791 of 16

Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com

Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204

Thank you for purchasing a Transfer Flow, Inc. 50-gallon replacement fuel system

for your 2011-16 Ford diesel short bed pickup. This system will fit any 2x4 or 4x4

crew cab vehicle. Please read the following procedures carefully before starting the

installation.

Do not have any open flame or heat sources close to the installation

area.

Due to the increased capacity of the Transfer Flow replacement fuel

system the vehicles “Distance To Empty” will no longer be accurate. Based on

the original capacity of Ford 26 gallon fuel tank and the Transfer Flow Inc.’s

capacity of 50 gallons, the customer can quickly determine a rough estimate of

the “DTE” by doubling the displayed value.

a video overview of this installation is available on youtube.com to watch the

video, search for “Transfer Flow, Inc.” or navigate directly to our channel by

entering www.YouTube.com/TransferFlowInc into your web browser.

Installation Instructions:

Disconnect the battery cables.

Removing the OEM tank:

1. Using a 5/16” socket, loosen the clamps securing the fill hose and vent hose to the OEM fill

neck. It may be necessary to remove the fill neck from the truck to gain access to the clamps.

To do this you will need to remove the three 7mm bolts from inside the fill door. Remove the

fill hose and vent hose from the OEM fillneck.

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2. Remove the OEM tank shield. There are 7 bolts and 2 nuts that need to be removed. Use a

13mm socket to remove the bolts and the 2 nuts. Bolts will be reused later on in the

installation. The 2016 uses M10 bolts with a 15mm head on bolt 1-4 shown below.

Some trucks might not have the rock shield on the bottom of the tank, but will

have the shield on the side of the tank. In this instance you will only have 4 bolts and 2 nuts.

OEM Fuel

Fillneck

OEM Urea

Fillneck

OEM Fuel

Vent Tube

OEM Vent

Hose

OEM Fill

Hose

OEM Driver

Frame Rail

OEM Fuel Tank

OEM Tank

Shield

OEM Front

Tank Strap

OEM Urea

Fillneck

Bolts 1&2 Bolts 3&4 Bolts 5&6

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3. Place a hydraulic jack underneath the OEM midship fuel tank. Raise the jack until contact

with the tank is made.

4. After making sure the tank is well supported, loosen and remove the OEM mounting straps.

Save all the strap bolts as they will be used later in the installation.

5. Lower the OEM midship tank approximately 6”, or until complete access to the OEM

sending unit can be made. It is easiest to get to the connections from the front of the tank.

6. Disconnect the electrical connector from the sending unit. First slide the red locking tab out

approximately 1/8” using either needle nose pliers or a small flat blade screwdriver.

Compress the release tab near the wire end of the connector and pull it away from the OEM

sender.

OEM Drive

Shaft

OEM Fuel

Tank

OEM Front

Tank Strap

OEM Rear

Tank Strap

Bolt 7

Nut 1 Nut 2

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7. Leave the tank at the same level and carefully disconnect the fuel supply and return fittings

from the draw and return tubes on the OEM sending unit. See the pictures on the next page to

safely disconnect the supply and return fittings.

2011-16 OEM fuel supply and return fitting latching tabs can be easily

broken. Review the disassembly procedure below before trying to disconnect these

fittings. Do not drop the tank any lower as the OEM fuel supply and return plastic fuel

lines are not designed for such movement.

Fuel may be under pressure and may leak from these disconnected fuel

lines. Keep the open ends away from any heat source, and place a drip pan beneath

them.

OEM Electrical

Connector

OEM ½” Supply

Fitting with

Yellow Tab

OEM 12mm

Return Fitting

with Blue Tab

OEM Electrical

Sender Connector

Locking tab

Release tab

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OEM Fuel Connector in

Latched Position

On Male Fitting

Pull Front

Colored Tab

Out As Shown

Depress Rear

Tab As Shown

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8. Completely remove the OEM fuel tank out of the vehicle.

BRACKET INSTALLATION:

9. Using a flat blade screwdriver, remove the OEM strap clip nuts from the front and rear

frame, and front and rear cross members. Both the inside OEM strap holes and the outside

OEM strap holes will be used to secure the new TFI fuel tank straps or TFI gusseted “L”

bracket.

10. Using a flat blade screwdriver, relocate the rear OEM strap clip nut to the position shown

below. Just above this clip nut is a bolt that holds an emergency brake cable support.

Remove this bolt.

11. Mount the rear TFI “L” bracket (040-01-13777) to the outside of the chassis frame rail.

Locate the bracket with the short leg facing toward the drive shaft. The bottom hole in the

TFI “L” bracket will be centered on the clip nut. Use one of the OEM M10 bolts that were

removed from OEM strap to secure the bracket to the frame. Reinstall the emergency brake

cable support using one of the longer bolts removed from OEM tank strap. Make sure that

the short leg of the TFI “L” bracket is parallel to the bottom of the driver’s frame rail. Refer

to Instruction Sheet #484 for proper torque specifications.

With Front Tab Out and Rear Tab Depressed Pull

Away From Male Fitting,

and Remove From Male

Fitting

Remove the Bolt that

Secures the E-Brake

Cable Support

New Location

for Rear OEM

Strap Clip

Nut

OEM Clip Nut in

OEM Location

Must Relocate

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BE CAREFUL NOT TO PINCH ANY WIRES OR FUEL LINES WHEN TIGHTENING

THE TFI “L” BRACKET FASTENERS.

12. Using a flat blade screwdriver, relocate the OEM strap clip nut located on the rear cross

member to the position shown below. There is a square hole and a round hole in the cross

member; this is where the clip nut will be placed.

13. In the front cross member, remove the OEM nut clip from the rear of the OEM cross member

and clip onto the middle hole in the front of the cross member. You can leave the other nut

clip in place; they will not be in the way.

Square hole in

OEM

Crossmember

Rear

Crossmember

OEM Clip

Nut in New

Location

OEM M10

Bolt

Reinstall E-brake

Cable Support

OEM Clip Nut in

OEM Location

Must Relocate

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14. 2011-15 reuse the OEM M8 bolts with OEM clip nut to mount the front strap.

15. 2016 place the provided M10 clip nuts before placing TFI tank in place.

OEM hole

that nut clip

goes over

OEM Drive

Shaft

Front

Crossmember

OEM Clip Nut in

OEM Location Must Relocate

OEM Nut

Clip in Final

Position

Single Piece

Drive Shaft

OEM Nut

Clip in Final

Position Two

Piece Drive

Shaft

Driver side

frame Rail.

2016 use provided

M10 clip nuts.

TFI TANK

Front strap mounting

Location.

2011-15 use

OEM M8

clip nuts.

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TFI TANK PREPARATION

16. Using a flat blade screwdriver and hammer, remove the cam ring from the OEM fuel tank.

Discard the OEM cam ring. Remove the OEM sending unit and OEM sender gasket from the

tank.

17. Carefully remove the OEM sending unit wire by pushing up on the wire until the wire comes

free from the clip. Remove the sending unit wire and discard.

18. Align the TFI sender wire onto the OEM sending unit and press into place.

OEM Sender

Cam Ring OEM Sending

Unit

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19. With the sending unit out of the tank, attach both leads of an ohmmeter to the metal

connections in the OEM sending unit connector. With the sending unit in the air and float at

the bottom stop, as if the tank were empty, the meter should read between 175-185 ohms.

Rotate the float wire to the top stop, as if the tank were full, and test to verify that the

resistance is between 7-14 ohms.

20. Before installing the sending unit into the TFI tank, place the TFI compression ring over the

OEM draw and return tubes on the top of the OEM sending unit.

21. Confirm that the surface the OEM sender gasket will rest on is clean and dirt free. Clean any

dirt or other debris with a damp rag. Place the OEM round sender gasket in the groove on the

TFI fuel tank at the sender opening.

22. Carefully position the OEM sending unit on top of the gasket. Orient the OEM sending unit

so the large locating tab falls in to the machined pocket on the TFI sender ring. The OEM

sending unit will only fit one way. The float should be facing towards the rear of the tank.

23. Place the TFI compression ring over the 6mm studs. Secure the compression ring to the tank

with (6) 6mm flange nuts. Refer to Instruction Sheet #484 for proper torque specifications.

24. Confirm that the rollover vent valve cam holes in the TFI tank are 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 into the cam ring on the TFI tank, the valve with

the longer attached hose goes into the rear of the tank by the fill neck. Rotate the valves

clockwise so the ports are pointing towards the driver’s side frame rail.

OEM

Sending

Unit

6mm

Flange Nuts

TFI

Compression

Ring

TFI Tank

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25. Reattach the ohmmeter leads to the sending unit. With the tank resting on level ground,

positioned as if it were in the vehicle, the resistance reading should again be between 160-

175 ohms. Turn the tank upside down so the float arm will fall into the full position. The

resistance meter should read between 7-14 ohms.

26. The tank must now be pressure tested. Seal off the supply and return tubes on the sending

unit, and the rollover vent valve. Pierce a small hole in the red plastic cap on the fill neck 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.

27. Remove the fill and vent hose from the OEM tank. You will need to cut these two hoses

down to size. The fillneck will need to be cut on both sides. Mark the fill hose with a paint

marker following the white location mark already on the hose up another inch or two.

28. Cut 1.5” off of the formed side of the fill hose, and 2” off of the straight side. Discard the two

short pieces. The vent hose will need to be cut at 12 ½” from the side without the 90° bend,

measure the hose without bending it straight. Discard the piece that you cut off with the bend

in it. Place the hoses on the TFI tank.

Keep this

piece

Discard this

Piece

Fill Hose Discard this

Piece

Keep this

Piece

Vent Hose

Discard this

Piece

This

Side to

the TFI

Tank

This

Side to

the TFI

Tank

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29. Secure both hoses to the tank with the OEM gear clamps. The side of the vent hose that you

measured from will be connected to the TFI tank, and the formed side of the fill hose will be

installed so that the mark on the hose is at the 12 o’clock position on the TFI tank. Refer to

Instruction Sheet #484 for proper torque specifications.

TFI TANK INSTALLATION:

30. Position the TFI fuel tank underneath the vehicle in the midship mounting location. The fill

and vent tubes must be facing toward the driver’s side frame rail.

31. Slowly raise the fuel tank while paying close attention to the electrical and fuel lines at the

water/fuel separator

32. As you are raising the fuel tank to its final position, care should be taken not to pinch the fuel

or vent lines or electrical convolute. Confirm that the fill and vent hoses are routed over the

top of the driver’s frame rail and that they are not routed near any sharp edges.

33. The alignment pin on the top rear of the tank must be inserted in the hole on the rear cross

member of the vehicle. You may need to rotate the top of the tank a towards the driver side

frame rail a little to insert the alignment pin into the crossmember.

Electrical

Fuel lines

TFI Tank Water

separator

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34. Loosely install the TFI rear strap using one OEM bolt, and one M10 x 35mm bolt and nut.

This strap will fit inside the strap guide on the tank. This guide will set the position of the

tank fore and aft.

35. 2011-15 loosely install the TFI front strap using two OEM M8 bolts, and one OEM M10

bolt. The picture below shows the two M10 bolts.

36. 2016 loosely install the TFI front strap using OEM M10 bolts.

Tank

Alignment Pin

The Tank

Alignment Pin

must be Inserted in

this Hole on the

Rear Crossmember

Drivers

Frame

Rail

DEF Tank

After Tank

Installation this

Brace Should Be

Resting Against

the Crossmember

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Two Piece Drive Shaft One Piece Drive Shaft

37. Confirm that the tank straps are hanging straight down and there is at least 3/4” of clearance

between the tank, differential and any part of the drive shaft. First, secure and torque the nuts

near the drive shaft on both straps. After the inside fasteners are secured, torque the outside

nuts. Refer to Instruction Sheet #484 for proper torque specifications.

38. If the OEM fillneck was disconnected from the OEM bezel, reconnect it with the three OEM

size bolts.

39. Reconnect the fillneck hose and vent hose to the OEM fill neck and vent tube. Secure the

hose connections with the OEM clamps. Refer to Instruction Sheet #484 for proper torque

specifications.

40. Now that the tank is secure the sending unit supply and return connections can be made.

Connect the electrical connector from the main harness to the OEM sending unit. Connect

the OEM fuel line fittings to the sending unit. Push the fittings together until an audible click

is heard. Push in the tabs to lock the connectors into place. Note that the fuel connections will

only fit one way.

OEM M8

Bolt

TFI Front

Strap

TFI

Tank

Frame

Rail

U-Shaped

Spacer

TFI Front

Strap

TFI Front

Strap

OEM

Carrier

Bearing

U-Shaped

Spacer

OEM Tank

Bolt

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FINALIZE THE INSTALLATION:

41. Make sure all fuel, fill 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 vent line has a

continuous downward slope from the fillneck to the fuel tank.

42. Make sure the bolts for the DEF tank are not hitting the TFI fuel tank. If the bolt is touching

the tank it may be necessary to loosen the DEF tank and move it back.

A. Locate the bolt on the driveshaft side of the DEF tank (Has a slotted mount).

B. Loosen this bolt to allow to tank to be moved away from the TFI fuel tank.

C. Move the DEF tank towards the rear of the vehicle and tighten the bolt .

D.

43. Reconnect the battery cables.

DEF slotted mount

for adjustment.

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44. 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.

The following are approximate gallon readings versus gauge position for the 50-gallon diesel

replacement system. Your system may vary depending on gauge and sender tolerances.

Gauge Gallons

EMPTY 5

¼ 14

½ 25

¾ 37

FULL 43 *Maximum Capacity = 50 Gallons

Tool List:

Hammer Flat Blade Screwdriver

15mm Socket 13mm Socket

7mm Socket 5/16” Socket / wrench

10mm Socket Ohm Meter Hydraulic Jack 13mm open-end box wrench

Torque Wrench Pliers

Ratchet Extension 10”

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