March 6, 2017 IS# 791 Page 1 of 16 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. area. Do not have any open flame or heat sources close to the installation 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.
March 6, 2017 IS# 791 Page 2 of 16 OEM Vent Hose OEM Fill Hose OEM Urea Fillneck OEM Urea Fillneck OEM Fuel Fillneck OEM Fuel Vent Tube 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 Front Tank Strap OEM Driver Frame Rail OEM Tank Shield OEM Fuel Tank Bolts 1&2 Bolts 3&4 Bolts 5&6
March 6, 2017 IS# 791 Page 3 of 16 Bolt 7 Nut 1 Nut 2 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. OEM Drive Shaft OEM Fuel Tank OEM Rear Tank Strap OEM Front Tank Strap 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.
March 6, 2017 IS# 791 Page 4 of 16 OEM Electrical Connector Locking tab Release tab 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 12mm Return Fitting with Blue Tab OEM Electrical Sender Connector OEM ½ Supply Fitting with Yellow Tab
March 6, 2017 IS# 791 Page 5 of 16 OEM Fuel Connector in Latched Position On Male Fitting Pull Front Colored Tab Out As Shown Depress Rear Tab As Shown
March 6, 2017 IS# 791 Page 6 of 16 With Front Tab Out and Rear Tab Depressed Pull Away From Male Fitting, and Remove From Male Fitting 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. Remove the Bolt that Secures the E-Brake Cable Support OEM Clip Nut in OEM Location Must Relocate New Location for Rear OEM Strap Clip Nut 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.
March 6, 2017 IS# 791 Page 7 of 16 Reinstall E-brake Cable Support OEM M10 Bolt 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. OEM Clip Nut in OEM Location Must Relocate OEM Clip Nut in New Location Rear Crossmember Square hole in OEM Crossmember 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.
March 6, 2017 IS# 791 Page 8 of 16 OEM hole that nut clip goes over Front Crossmember OEM Clip Nut in OEM Location Must Relocate OEM Nut Clip in Final Position Single Piece Drive Shaft OEM Drive Shaft OEM Nut Clip in Final Position Two Piece Drive Shaft 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. 2011-15 use OEM M8 clip nuts. Driver side frame Rail. 2016 use provided M10 clip nuts. TFI TANK Front strap mounting Location.
March 6, 2017 IS# 791 Page 9 of 16 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. OEM Sending Unit OEM Sender Cam Ring 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.
March 6, 2017 IS# 791 Page 10 of 16 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. OEM Sending Unit TFI Tank 6mm Flange Nuts TFI Compression Ring 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.
March 6, 2017 IS# 791 Page 11 of 16 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 Fill Hose Discard this Piece This Side to the TFI Tank Discard this Piece Keep this Piece Vent Hose This Side to the TFI Tank Discard this Piece
March 6, 2017 IS# 791 Page 12 of 16 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 TFI Tank Water separator Electrical Fuel lines 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.
March 6, 2017 IS# 791 Page 13 of 16 After Tank Installation this Brace Should Be Resting Against the Crossmember Tank Alignment Pin Drivers Frame Rail The Tank Alignment Pin must be Inserted in this Hole on the Rear Crossmember DEF Tank 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.
March 6, 2017 IS# 791 Page 14 of 16 Two Piece Drive Shaft One Piece Drive Shaft U-Shaped Spacer OEM Carrier Bearing U-Shaped Spacer OEM Tank Bolt TFI Front Strap TFI Front Strap OEM M8 Bolt Frame Rail TFI Front Strap TFI Tank 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.
March 6, 2017 IS# 791 Page 15 of 16 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). DEF slotted mount for adjustment. 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.
March 6, 2017 IS# 791 Page 16 of 16 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