Thank You For Purchasing A Transfer Flow, Inc. Trax3tm Fuel System For

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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 April 11, 2017 IS# 877 Page 1 of 30 THANK YOU FOR PURCHASING A TRANSFER FLOW, INC. TRAX3TM FUEL SYSTEM FOR YOUR 1999-2017 FORD SUPER DUTY DIESEL. THIS SYSTEM IS NOT INTENDED FOR USE ON ANY GAS VEHICLE. 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. DUE TO THE 2017 F SERIES TRUCK BODIES BEING ALUMINUM SPECIAL PRECAUTIONS NEED TO BE MADE WHEN SECURING THE TANK TO PREVENT COROSION. PLEASE READ THE FOLLOWING PROCEDURES CAREFULLY BEFORE STARTING THE INSTALLATION. CAUTION: DO NOT OVER FILL. 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 April 11, 2017 IS# 877 Page 2 of 30 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. • Feet are on the side of the 30 & 50 gallon aluminum diamond plate toolbox tanks, also the 50 gallon and 98 gallon steel cross the bed tanks. Mounting feet on the side of the tank Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 • • • Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 3 of 30 Feet are on the front and back sides of 75 gallon cross the bed tanks, 40 gallon steel toolbox tanks, and 100 gallon aluminum diamond plate cross the bed hauler tank. 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: Preparing the Auxiliary Tank Roll Test Tank to Verify Auxiliary Sending Unit Function 7. Using an ohmmeter measure the resistances signal at the auxiliary sending unit. Attach the leads to the sending unit ground and signal. With the tank resting on level ground, positioned as if it were in the vehicle at empty, the resistance reading should be 22-28 ohms. Turn the tank upside down so the float arm will fall into the full position. The resistance should read between 262-272 ohms. • *The following in-bed aux tanks will have a different resistance at empty; 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 April 11, 2017 • • • • • IS# 877 Page 4 of 30 37gal in-bed = 28Ω 40gal Tool Box = 40Ω 75gal in-bed = 36Ω 98gal in-bed = 33Ω (Aluminum Diamond Plate) 100gal in-bed = 36Ω (Aluminum Diamond Plate) Ground Signal Pre-position the Tank in the Bed of the Truck 8. 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. 9. 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. 10. Remove the tank from the mounting area. 11. Measure the mounting hole locations using the head gate and bed corrugations as reference. 12. Crawl under the truck. 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 April 11, 2017 IS# 877 Page 5 of 30 13. 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. 14. 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. 15. Move any wires, hoses or obstructions that may be scarred by a drill bit. 16. 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. 17. Get ready to start drilling (you will be drilling from the top down). 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 April 11, 2017 IS# 877 Page 6 of 30 Section 3: Mount the Tank 18. Drill pilot holes with a long 1/8” drill bit. Did the pilot hole come through the bottom where you expected? 19. 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. If you do fuel lines and electrical wiring can be damaged. (2) 1 ¼” holes in box side panel Front of the truck. 20. Enlarge the holes for the hoses and wiring harness with a 1 ¼” hole-saw. Insert the provided rubber grommets into each hole. 21. Enlarge the tank mounting holes with a 9/16” drill. 22. All holes drilled in the vehicle need to be painted in order to reduce the risk of corrosion. 23. 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. NOTE: If the bed of the truck has a sprayed on or plastic bed liner the rubber strips may not be required. 24. Place the tank in its final position. 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 April 11, 2017 IS# 877 Page 7 of 30 This is a 75 gallon cross the bed tank your tank may be different than pictured. 25. Place shims under the mounting brackets to prevent the corrugations from collapsing. See drawing below. On 2017 F series trucks the use of foam is necessary on the shim for the mounting hardware. Please refer to the Ford QVM bulletin Q-222R Foam supplied in kit 26. Insert the 1/2” carriage head bolts through the mounting brackets and bed. Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 8 of 30 27. Secure fasteners with washers and nuts and torque the nuts. Refer to Instruction Sheet #484 for proper torque specifications. *On some vehicles it may be necessary to install the carriage bolt from under the truck. Place one shim on the head side of the bolt before installing in the bed hole. On the tank feet use one shim and the ½” flange nut to secure the tank. Tank mounting bracket 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 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. 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 April 11, 2017 IS# 877 Page 9 of 30 SECTION 4: PLUMBING THE SYSTEM Vent Hose TRAX3TM Module Fuel Transfer Hose Rollover Vent Valve Fuel Pump Fuel Filter Sending Unit Components underneath cover box on top of cross the bed tank. 28. Make sure the fuel transfer hose is hooked up to the TFI fuel pump. 29. Route both the transfer and vent hose though one of the grommets in the pickup bed. 30. Crawl under the truck. SINGLE TEE INSTALLATION ON 1999-2016 MODEL VEHICLES. 31. 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 Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 10 of 30 2017 Model year vehicles with require the removal of the fill hose off the fill neck to provide access to the tank side of the vent hose were the connection should be made. Tee placement for 2017 Tank side of vent hose 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. Install single tee in the main tank fillneck vent hose Do not make any modifications to DEF tank fillneck Front of the truck. Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 11 of 30 32. 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. NOTE: Make sure there isn’t a P-trap in the vent hose after the single tee installation. This can cause problems when filling the main tank. 33. Install the provided hose clamps onto the large ends of the single tee. Refer to Instruction Sheet #484 for proper torque specifications. 34. 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. Besure there are not any sharp bends or kinks in the hose. 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 35. Attach the fuel transfer hose to the single tee with the provided hose clamp. Refer to Instruction Sheet #484 for proper torque specifications. 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 April 11, 2017 IS# 877 Aux Supply Line Page 12 of 30 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. 36. Find the TFI vent 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. Trim the vent hose to length if necessary. 37. 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 Section 5: Wiring the System 38. Find the TRAX3TM wire harness. 39. Mount the TRAX3TM module to the tank. If you have a TRAX3TM Toolbox, the module will mount inside of the tool box underneath the cover box with supplied Velcro. 40. 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. 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 April 11, 2017 IS# 877 TRAX3TM Module Module mounted with Velcro Page 13 of 30 TRAX3TM Module Mount module to tank stud and secure with nut AUX Sender 41. Connect the fuel pump, aux sender, power, and 10-pin connector on the wiring harness to the TRAX3TM 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. • • • • Fuel Pump: Three pin connector w/tan & black wires to three pin connector w/orange and black wires. Aux Sender: Spade connector w/purple wire to the top center of sender. Ring terminal w/black wire to ground stud on sender. Power: Three pin connector w/red & black wires to three pin connector w/red and black wires. 10-Pin Connector to TRAX3TM Computer Module. Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 14 of 30 TRAX3TM Module 42. Route the wiring harness through the unused bed grommet. 43. Crawl under the truck to the frame-rail area near the fill hose and single tee. 44. Find the OEM wiring harness that runs inside of the frame rail (2017 top outside of the frame). In the section just in front of the OEM fuel tank peel back about 5” of the plastic/tape cover from the wire harness to expose the wires inside. If working on a Cab Chassis having only an aft axle tank you will need to open the OEM wire harness closer to that tank. Pay attention to the next few steps; they are critical to making sure the system works correctly! If you accidently cut or tie into the wiring for the DEF system. This will cause the truck to go into a tamper mode thinking you are modifying or removing the DEF system. Which will cause the truck to go into a Limp Mode. Only the Dealer can clear this code! 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 April 11, 2017 IS# 877 Page 15 of 30 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 2012 2013 2014 2015 2016 2017 Yellow wire with Purple Stripe Green wire with Blue Stripe Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 16 of 30 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. Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 17 of 30 53. 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. 54. 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”. 55. 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 labeled in step #53. Make this connection with the 18-22 gauge butt connector and insulate the connection with the supplied heat shrink. 56. Find the TFI GREEN wire. Connect the TFI GREEN wire to the gauge side of the ground wire that you labeled in step #523. Make this connection with the 18-22 gauge butt connector and insulate the connection with the supplied heat shrink. Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 18 of 30 57. 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. 58. 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. 59. Crawl under the truck to an area underneath the cab near the driver’s frame rail. Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 19 of 30 Section 6: Electrical Power Connection 60. Route the end of the harness with the red connector, the red power wire and black/white ground wire towards the fuse box and 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. Like the automatic transmission shift cable grommet behind the accelerator pedal. 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. 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. • 2008-2011 Model Vehicles the fuse box is located in the passenger kick panel. • 2012-2016 Model Vehicles the power should be received from the up fitter power access (customer access) under the driver’s side dash near parking brake. • 2017 The customer power access is located on the passenger side of the cab with the fuse box. 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 April 11, 2017 IS# 877 Page 20 of 30 • Reconnect the vehicle’s battery. • 1999-2016 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 This leg into hot side of fuse box Figure 1: Tap-a-Fuse with fuses installed • 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. SEE FUSE CHART ON NEXT PAGE 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 April 11, 2017 IS# 877 Page 21 of 30 Ford Fuse Locations Year 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 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Uses up fitter harness under the drivers side dash near parking brake Customer access White with blue stripe Green with orange striped wire in passenger kick panel Supplied 5 amp inline 2016 2017 Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 22 of 30 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 April 11, 2017 IS# 877 Page 23 of 30 2012-2016 power location Emergency brake Up fitter harness White with blue stripe Brake pedal Supplied inline fuse holder and supplied 5 amp fuse 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 April 11, 2017 IS# 877 2017 power Page 24 of 30 Green with orange wire 2017 power power location Ground stud Passenger side kick panel • 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. 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. ELECTRICAL GROUND CONNECTION: 64. At the forward end of the TRAX3TM wire harness you will find a black with white stripe ground wire. NOTE: This ground wire must be attached to the vehicle or the TRAX3TM 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 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 April 11, 2017 IS# 877 Page 25 of 30 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. Find the supplied TRAX3TM wiring harness and locate the end with the red connector. Red Connector 66. Feed the red connector through the grommet in the floor. 67. Assemble the provided Ram-Mount per diagram below (style may vary) Sticky back style mount Mount to the back of LCD Bolt & Nut Mount to windshield or dash Small Screw CAUTION: Use only the machine screws provided in this kit. These screws are a specific type and length!! If you use sheet metal screws or longer machine screws they will poke through and destroy the computer board. 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 April 11, 2017 IS# 877 Page 26 of 30 Suction cup style mount Supplied machine screws 68. Find the TRAX3TM LCD and decide on a suitable mounting location. The most popular place to mount the module is on the left hand side of the dash board near the windshield pillar. TRAX3TM LCD Mounting the LCD near the driver's windshield pillar makes reading the display easy. 69. From inside the cab pull enough of the TFI wire harnesses through the grommet to reach the location you have chosen for the TRAX3TM LCD. Note that you will want to hide the wire harness behind removable panels and carpeting as much as possible to keep the harness protected and out of sight. Make sure the wire harness will not tangle or obstruct the parking brake, gas pedal or brake pedal. 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 April 11, 2017 IS# 877 Page 27 of 30 70. Plug the red connector into the back of the TRAX3TM LCD, taking care to not bend or damage the pins on the back of the LCD. Round base attaches to windshield using the provided adhesive pad. Clean glass and round base with alcohol swab. Ball mount attaches to module with provided screws. USE ONLY THE MACHINE SCREWS PROVIDED IN THIS KIT!! Socket mount attaches to round base with provided screws and nuts. The red connector plugs into the TRAX3TM LCD in this orientation. 71. Mount the LCD in your chosen location using the supplied bracket and adhesive pad. Make sure to clean both adhesive surfaces with the provided alcohol swab. • CAUTION: Locate the LCD in such an area that no impact injury will occur in the case of a vehicle collision (particularly frontal impact). No attempt should be made to locate the LCD in the knee bolster area, which is directly below, and to the immediate left or right of the steering wheel. • The adhesive pad that we supply can only be applied once, so it is important that you have planned the LCD location carefully prepare the surface of the windshield. 72. 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. 73. 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. 74. Reconnect the battery. 75. Fill the Auxiliary tank up with fuel. 76. 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. 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 April 11, 2017 IS# 877 Page 28 of 30 Tire & Loading Label This kit comes with a new Tire & Loading Label. Update the new label and place it directly over the old label. 77. Perform the TRAX3TM test and verification procedure, see IS #874. Door Post Label The Silver Label should be affixed to the door post 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 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 April 11, 2017 IS# 877 Page 29 of 30 • 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 TRAX3TM Wire Harness Diagram Transfer Flow, Inc. 1444 Fortress Street Chico, CA 95973 www.transferflow.com April 11, 2017 Phone: (530) 893-5209 Sales/Tech: 1-800-442-0056 Fax: (530) 893-0204 IS# 877 Page 30 of 30