Your Legal Fuel Tank Source.

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1 July 02, 2014 IS#836 Page 1 of 22 THANK YOU FOR PURCHASING A TRANSFER FLOW, INC. MAXFLO-TFI FUEL SYSTEM FOR YOUR FORD SUPER DUTY DIESEL OR YOUR 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.

2 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.

3 July 02, 2014 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.

4 July 02, 2014 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.

5 July 02, 2014 IS#836 Page 5 of 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 Tail Gate Hat Sections Front of Vehicle Corrugations 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).

6 July 02, 2014 IS#836 Page 6 of 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.

7 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.

8 July 02, 2014 IS#836 Page 8 of 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.

9 July 02, 2014 IS#836 Page 9 of Crawl under the truck. 29. SINGLE TEE INSTALLATION ON 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 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.

10 July 02, 2014 IS#836 Page 10 of 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 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.

11 July 02, 2014 IS#836 Page 11 of 22 Aux Supply Line 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 Model Vehicles: If you are working on a short bed, make sure the OEM vent hose is reattached to the OEM tank.

12 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 MaxFlo- TFI 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.

13 July 02, 2014 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.

14 July 02, 2014 IS#836 Page 14 of 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 Yellow wire with White Stripe Yellow wire with Purple Stripe Black wire with Orange Stripe Not Black wire with Pink Stripe! Green wire with Blue Stripe

15 July 02, 2014 IS#836 Page 15 of 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 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 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 gauge butt connector and insulate the connection with the supplied heat shrink. 52. Cut the OEM sending unit ground wire.

16 July 02, 2014 IS#836 Page 16 of 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 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 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.

17 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 Model Vehicles the fuse box is located under the steering column 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 SEE FUSE CHART ON NEXT PAGE Figure 1: Tap-a-Fuse with fuses installed

18 July 02, 2014 IS#836 Page 18 of 22 Ford Fuse Locations Year Location of Fuse Panel Fuse ID Number Fuse panel is located under the steering column, behind a removable panel. Fuse panel is located behind the passenger side kick panel. Fuse #33 Fuse #34

19 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.

20 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 MaxFlo- TFI 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.

21 July 02, 2014 IS#836 Page 21 of 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 Long 1/8 drill bit Hose cutters 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 Wire strippers 7mm socket Extensions 8mm socket ¾ socket

22 March 12, 2014 IS#836 Page 22 of 22

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