Aftermarket & OEM Fuel Tanks 1444 Fortress Street Toolbox ......Retrofit Fillneck Kits Auxiliary...

December 4, 2015 IS# 803 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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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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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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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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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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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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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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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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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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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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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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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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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

Aftermarket & OEM Fuel Tanks 1444 Fortress Street Toolbox ......Retrofit Fillneck Kits Auxiliary...

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Transcript of Aftermarket & OEM Fuel Tanks 1444 Fortress Street Toolbox ......Retrofit Fillneck Kits Auxiliary...