Locking Gas Cap

This may not seem like much of a "modification", but it is cheap

insurance to keep your fuel clean. The locking gas cap is a Ford

product available at the parts counter.

Pre-Fuel Pump Modified

This modification is necessary due to the poor connections used

by Ford to make up the fuel lines. The stock, plastic quick

connects and metal lines are replaced with rubber fuel hose and

sealed with hose clamps. This drastically reduces the amount of

air being introduced into the fuel lines and thus the injectors.

Fuel Tank Sending Unit Modified

The fuel system from Ford has several points along it's path

which introduce air into the flow of fuel to the engine. One of

these is the sending unit, which is located inside the fuel tank.

There are many kits available to modify the sending unit to

eliminate the air which is picked up by the stock sending unit.

Transfer Flow Fuel Tank

The stock fuel tank was 29 gallons. This gave a range of about

350 - 400 miles. The Transfer Flow replacement tank is 46 gallons.

This gives a range of about 650 - 700 miles, depending on current

fuel economy. The Transfer Flow tank is all steel as opposed to

the stock tank which is some form of plastic. The stock plastic

tank was very light. Probably around 15 - 20 lbs. in weight.

Whereas, the new tank alone is around 150 lbs.

Distance to Empty Reprogrammed

The overhead console's "Distance to Empty" function is the only

reprogramming necessary when adding a larger fuel tank. In it's

stock configuration, it is programmed to recognize a full tank as

29 gallons. This parameter can be changed to any value within a

given range. The area of the truck's computer to access is the

"OTC." This stands for "Over The head Computer." There are

several options that can be selected from a list once in this area.

They are: 18 gallon, 29 gallon and 38 gallon. There is also an

option with blanks that can be filled in that looks like this on the

readout _ _ _ _ . _ . In my case what needed to be entered was

0046.0. All of this was accessed with the New Generation Star

scanning tool. Reprogramming this parameter now allows the

"Distance to Empty" readout to be more accurate.

Dahl Heated Fuel FIlter

Adding a Dahl fuel filter is just another measure to ensure the

engine is receiving clean fuel. Of course, the engine has it's own

fuel filter / water separator, but there is no such thing as too

much filtering. The Dahl filter removes water and, at the same time,

filters the fuel for contaminents. Also, the Dahl filter is placed

before the fuel pump, which provides protection to the pump that

the OEM filter does not. I simply fabricated a bracket and

attached the filter assembly to the floor of the truck, with

stainless steel hardware. The filter has a heating element, which

can be controlled by a switch. At this time, though, I have not

wired it up due to the mild winters in North Carolina.