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July 14, 2010 IS #752 Page 1 of 19

THANK YOU FOR PURCHASING A TRANSFER FLOW, INC. TRAX-II FUEL

SYSTEM FOR YOUR 2001-2010 GM 2500-5500 DIESEL OR YOUR 2001-2003 GM 2500-
3500 FUEL INJECTED GAS VEHICLE WITH NON-CALIFORNIA EMISSIONS. THIS
SYSTEM IS NOT INTENDED FOR USE ON ANY GAS VEHICLE THAT IS
CERTIFIED TO CALIFORNIA EMISSIONS.

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.

Section 1 Plumbing the system

1. Install the Trax-II sending unit. Unbolt the pump if necessary and slide it out of the way
(you should not have to disconnect the hoses). Remove the sending unit cover plate by
loosening the 5 nuts that retain the round cover plate. Apply Permatex 2A to both sides
of the supplied cork gasket and carefully place the gasket over the studs. Make sure that
the holes in the gasket line up perfectly with the studs on the tank. Note that the stud
pattern is not symmetrical. Carefully feed the sending unit through the opening in the
tank and place it over the studs. The pattern of the studs will only allow the sending unit
to seat in one orientation. Refer to Instruction Sheet #484 for proper torque
specifications. Attach the pump and ground wire.

You may need to temporarily

move the fuel pump to gain
access to the sending unit
opening. The hoses can
remain connected.

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Apply Permatex 2A to
both sides of the new
cork gasket and install the
sending unit. The pattern
of the studs will only
allow the sending unit to
install in one orientation.

Note: the above pictures apply to cross the bed tanks. Toolboxes will look different but be
similar to install.

2. 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 should be attached to the tank and
grommets should be installed in the two holes for the wire harness and hoses. If
installing a toolbox tank make sure the lid functions without rubbing the bedrails or
headgate.

3. Make sure the fuel transfer hose is hooked up to the TFI fuel pump. Locate the other end
of this hose and label it “supply” using a strip of masking tape.

4. Route both of the hoses though one of the grommets.

5. Open the fuel fill door and remove the three screws that retain the fillneck assembly
using a 7 mm socket.

6. Crawl under the truck. REFER TO THE ILLUSTRATIONS ON PAGES 4 & 5 FOR
INSTUCTIONS #7 through #15.

7. Remove the clamp that attaches the fill hose to the OEM fillneck.

8. Mark the fill hose 2” from the edge of the frame rail.

9. Pull the OEM fillneck down towards the ground until it is pointing under the bed side
panel.

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10. Remove the OEM fillneck completely from the vehicle. On 2001-2004 trucks you will
see that the OEM fillneck has an internal fill hose that runs inside of the 2” hose.
Continue pulling on the fillneck assembly until the internal fill hose is completely free
from the truck. Do not cut the internal fill hose.

11. Cut the 2” hose at the spot you marked in step #8. Remove an additional 1/2” of hose
from the fillneck end of the hose. Do not cut the internal fill hose.

12. Place a large hose clamp on either side of the single tee.

13. Install the provided single tee into the 2” hose. The 3/8” nipple of the tee needs to point
towards the outside of the truck and be rotated in an upwards fashion (10-2 o’clock
position). Do not let the nipple point downhill.

14. Insert the inner fill tube and fillneck into the 2” hose and tighten the hose clamps. Refer
to Instruction Sheet #484 for proper torque specifications.

15. Re-install the OEM fillneck to the truck body using the three OEM screws.

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Follow these steps to install the single tee. If you have a 2004-LLY or newer, disregard step #3 and
step #6. 2004-LLY and newer trucks do not have an inner Fill tube.

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Follow these steps to install the single tee. If you have a 2004-LLY or newer, disregard step #3
and step #6. 2004-LLY and newer trucks do not have an inner fill tube.

16. Secure and torque the provided hose clamps onto the large ends of the “single tee.” Refer
to Instruction Sheet #484 for proper torque specifications.

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Aux Supply
Line

OEM 2” Fill
Hose
Single Tee
Front of Vehicle

This photo shows the single tee when it is completely installed on a 2006 GM truck.

17. 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 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.

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.

18. 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.

Section 2 Wiring the system

19. Open the hood of the truck.

20. Find an OEM grommet that can be modified to accept the TFI wiring harness. Here are
some possibilities:

• OEM grommet on firewall, underneath the Brake Master Cylinder

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• 2007-2010 OEM grommet on firewall inside of the cab, located behind relay box.
Remove the cover from the relay box; gently pull the relay box away from its
cradle. The grommet should be visible with the relay box moved out of the way.

OR

• Remove the sill plate and kick panel on the driver’s side. Pull back the carpeting
to expose a rubber OEM grommet in the driver’s foot well.

21. Pull back the carpet and padding away from the grommet.

22. Crawl under the cab of the truck.

23. Modify the OEM grommet so that the TFI wire harness can pass through. Make sure that
no hot or sharp metal edges are exposed which may cut the harness or shifter cable.

24. If none of the above options are viable, the last possibility is to drill a 1 ¼” hole in the
floor board, route the harness through the hole until all the large parts are past the
opening. Slit the provided ½” ID by 1 ¼” grommet; insert it over the wire harness and
into the drilled hole. After all wires and connectors are attached, use adhesive to bond
the slit and fill the open space between the wiring convolute and grommet.

25. Find the supplied TRAX-II wiring harness and locate the end with the red connector
attached.

Red Connector

Relay Socket

26. Feed the red connector, relay socket and 3 feet of wire harness through the grommet in
the floor. Make sure the Black, Black w/ White stripe wires remain outside the cab while

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the red wire is inside the cab. For 2007 to current model vehicles leave the red wire
outside of the cab.

Red Connector

Red, Black, Black w/ Relay Socket

White stripe.

To Fuse Panel
Fire Wall Grommet

To OEM harness and TFI tank.

Front of Vehicle

27. Assemble the provided Ram-Mount to the Trax-II module following the illustration in
step 30.

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.

28. Find the TFI Trax-II computer module 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. Other options include low on the dash near the transmission hump.

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Trax-II Module

Mounting the module near the driver's windshield pillar makes reading the display and operating the controls easy to do

29. From inside the cab pull enough of the TFI wire harnesses through the grommet to reach
the location you have chosen for the Trax-II computer module. 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.

30. Plug the red connector into the back of the Trax-II Module taking care to not bend or
damage the pins on the back of the module.

Socket mount
attaches to round
base with
provided screws
Ball mount attaches to
and nuts.
module with provided
screws. USE ONLY
THE MACHINE
SCREWS PROVIDED
IN THIS KIT!!

Round base attaches to

dash using the provided
adhesive pad. Clean
dash and round base with
alcohol swab.

The red connector plugs into the Trax-II module in this orientation.

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31. Mount the module 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 Module 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 module 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 module location carefully and that the dash is VERY clean.
TFI provides an alcohol swab to prepare the surface of the dash board.

32. Find the relay socket that extends out of the TFI harness. Install the supplied 30 amp
relay into this socket and secure the relay out of sight with a cable tie.

Relay Socket
30 Amp Relay

30 amp relay installed in socket

33. Find these TFI wires and route them to the vehicle’s fuse box in the engine compartment:
Red, Black and Black w/ White stripe.
34. Connect the red power wire to the vehicle’s fuse box.
• Route the red wire to the fuse box.
• Trim the red wire to length and install the fuse tap using the supplied 18-22 gauge
crimp connector and seal the connection with the supplied heat shrink tube.
• Reconnect the vehicle’s battery.
• Find a keyed-on fuse. Remove the fuse from the fuse box. Slip one leg of the fuse
into the fuse tap. The inline fuse adapter has an ATM fuse tap attached to one

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lead. The ATM fuse tap will fit the small mini fuses. If your truck has the larger
style fuses, then replace the ATM fuse tap with the supplied ATC fuse tap.

ATM Fuse Tap

ATC Fuse Tap

The TFI harness is supplied with mini style (ATM) fuse tap already installed. If your truck has the larger ATC fuses (as
shown in the foreground) you will need to cut off the small fuse tap and replace it with the large fuse tap that is supplied
in the kit.

SEE FUSE CHART ON NEXT PAGE

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Use this chart as a guide to find the correct fuse. Double check that the fuse you select is only hot when the key is turned
to the on position.

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• Insert the fuse back into the fuse box. Make sure that the leg of the fuse with the
newly installed tap 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.

The fuse tap must

connect to the hot
side of the OEM
fuse.

PLEASE NOTE: The fuse must be pushed through the slot in the fuse tap as shown in this drawing. You can determine
which side of the fuse is hot by removing the fuse and probing the fuse socket with a test lamp or volt meter. Make sure
the ignition is on and the battery connected when you run this test.

35. Check underneath the cover on the TFI inline fuse holder. There should be a 5 amp fuse
installed. Verify that the fuse is there.
36. Replace the fuse panel cover. You may need to cut a notch in the edge of the fuse panel
cover to allow the new wire to pass through.
37. Attach the ground wires. Find the TFI black wire and TFI black wire with white stripe.
These must be attached to a suitable ground. Look in the engine compartment for a
ground lug that has OEM grounds attached; ground these wires to the OEM ground using
the supplied #10 eyelets and #10 star washer. Look for an OEM ground on the frame
behind the driver’s front tire. If no OEM ground is available you will need to ground
them 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 eyelets and #10 star washer from the
TFI kit. Route the (2) black wires, one with a white stripe in the TFI harness, to the
hole location on the frame. Secure each wire to a #10 eyelet. Using a #10 sheet
metal screw and #10 star washer, ground these eyelets to the frame. Coat the ground
connection with dielectric grease or Kopr-shield.

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38. Cover any exposed wires with the extra convolute supplied in this kit. Secure the wire
harness with zip ties. Make sure that the harness is not hanging loose or routed so that it
can get tangled in the e-brake mechanism or the driver’s feet. Make sure the harness is
not rubbing on anything that is sharp or hot.
39. 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.

40. Pay attention to the next few steps; they are critical to making sure the system correctly
functions!

41. Find the OEM sending unit signal wire and sending unit ground wire by comparing the
wire colors on this chart:

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42. Cut the sending unit signal wire.

43. Verify that you have cut the correct wire by performing this test:

• Temporarily hook up the vehicle’s battery.

• 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 the gauge does not react within 5 minutes of the
ignition being switched on, you have cut the wrong wire and need go back to step
40. Repair the mistaken wire and cut the correct one.

• Key the ignition off.

• Disconnect the battery.

44. 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”.

45. Locate the TFI wire harness and route the yellow wire, white wire and black wire with
white stripe to the area that you are working. Make sure the wire harness is not rubbing
on any hot or sharp objects or interfering with the vehicle’s other systems such as e-brake
cable, fill and vent hoses or TFI tank mounting bolts.

46. Connect the TFI YELLOW wire to the wire you have labeled “GAUGE”. Make this
connection with the 18-22 gauge butt connector and insulate the connection with the
supplied heat shrink. SEE ILLUSTRATION NEXT PAGE

47. Connect the TFI WHITE wire to the wire you have labeled “SENDER”. Make this
connection with the 18-22 gauge butt connector and insulate the connection with the
supplied heat shrink. SEE ILLUSTRATION NEXT PAGE

48. Find the OEM Sending Unit Ground Wire, SEE GM SENDING UNIT WIRE COLOR
CHART.

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49. Cut the OEM sending unit ground wire.

50. Find the TFI black with white stripe wire. Connect this wire to both sides of the OEM
sender ground with a butt connector and supplied heat shrink.
CAUTION: 2007-2010 VEHICLES (DO NOT cut either of the tan wires that are
twisted together, these wires go to the rear axle speed sensor.) SEE ILLUSTRATION
BELOW

Sending Unit Wire Schematic

51. 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.

52. Route the TFI harness to the rear 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.

53. Find the connections for the TFI pump and sending unit on the TFI wire harness. Route
this end of the harness through the unused grommet that you installed in the bed.

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54. Connect the harness to the fuel pump and sending unit. Both of these connections can be
accessed by removing the cover box on top of the TFI tank.

55. Crawl under the truck and examine the wire harness. Make sure that the entire harness is
secured along the frame in a manner that will not allow it to hang below the chassis or get
tangled with any moving parts. Make sure the harness is not rubbing on anything sharp
or hot. The harness should be snug but not pulled tight.

56. Double check your work: At this point the wiring should be complete. The pump is
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
two ground wires are secured and the red power wire is tapped into the fuse box. The
module is mounted to the dash and plugged in to the Trax-II harness. If all of these tasks
are complete, then you are ready to add fuel to the system.

Section 3 Testing the System

57. Reconnect the battery.
58. Fill up the Auxiliary Tank; do not add fuel to the Main Tank.
59. Remove the gas cap on the Main Tank.
60. Press both buttons on the Trax-II module.
61. While holding both buttons down, turn on the ignition. You do not need to start the truck.
62. Hold the buttons until you see the serial number of the Trax module displayed on the
screen. When you see the serial number, release both buttons.
63. Follow this sequence to access the pump test screen.
1. DTC Screen = press “next”
2. Diagnostic Screen = press ”next”
3. Time Screen = press “next”
4. Flow Test Screen = press “enter”
5. Flow Test Screen = press “start”
64. Once you have entered the Flow Test, the display will read PUMPON. Leave the key on
and exit the truck. Put your ear next to the OEM fillneck and listen to the pump run. The

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first sounds you hear will be the pump priming itself followed shortly by the sound of
fuel being pumped into the fillneck. If the Main Tank is already FULL, do not run
this test any longer than necessary to verify that the pump is working. Running the
flow test when the main tank is FULL can cause an overfilling of the Main Tank
and fuel will spill out of the fillneck. The pump will transfer 1 gallon of fuel in 3
minutes.

65. Shut off the Flow Test by turning the ignition key to the “OFF” position.

66. Crawl under the truck and check your plumbing connections for leaks.

67. If you need to check the flow of fuel coming from the TFI system for trouble shooting
purposes you can do so by disconnecting the TFI supply line from the TFI single tee.
Place the loose end of the supply hose into a fuel can and start the Flow Test as described
in Step 63. The TFI system should fill a 1 gallon gas can in 3 minutes. At the end of the
flow test, reconnect the supply line to the tee and double check your hose connections for
leaks.

68. If you are unable to complete this test, contact TFI for further technical assistance.
1-800-442-0056

69. Double check your work. At this point you should give the entire system one last
inspection to make sure you haven’t missed anything. Ask a friend to look at the system
while you describe the steps you followed. Make sure they don’t see anything out of the
ordinary or out of place.
70. Fill the Main tank up with fuel (if you choose) and make sure both fuel caps are in place.
71. Find the TRAX-II User’s Guide that came with the kit and place it in the glove
compartment for future reference.
72. 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.

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Tire & Loading Label

This kit comes with a new Tire & Loading Label. Update the new label and place it directly over the old label

Door Post Label

The Silver Label should be affixed to the door post

73. 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
7/8” drill bit 0-50 ft-lb torque wrench
1 ¼” hole saw Ratchet
Diagonal cutters Extensions
Wire strippers ¾” socket
7mm socket

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