GlowShift | 1999-2007 Ford Super Duty 7.3L / 6.0L Powerstroke Installation Guide

INSTALLATION GUIDE 99-07 FORD SUPER DUTY 7.3/6.0 POWER STROKE 1999-2007

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE TABLE OF CONTENTS SECTION 1 Boost Gauge Installation 1 SECTION 2 Pyrometer EGT Gauge Installation 4 SECTION 3 Transmission Temp Gauge Installation 5 SECTION 4 Fuel Pressure Gauge Installation 6 SECTION 5 HPOP Gauge Installation 8 SECTION 6 Installing The Pillar Pod 9 SECTION 7 Connect to Power 11 GlowShift Installation Guides are designed so that you don’t need to be a professional mechanic to install our products. Whether you’re a beginner or a seasoned pro, we’ll walk any Do-It-Yourselfer through every step of the process for installing our gauges, gauge pods and accessories. The custom gauge package featured in this guide is a popular combination gauge and pod set for the 1999-2007 Ford Super Duty F-250 and F-350 with a 6.0L or 7.3L Power Stroke. Before getting started, confirm you have the tools and accessories below and let’s get to work. For MaxTow® Gauges, the wire colors on the gauge power harnesses are different than what appears in this installation guide. Additionally, for the Boost Gauge, please follow the same steps but instead of installing the brass compression fittings and boost line, thread the 1/8-27 NPT boost sensor into your desired location and tighten with a 22mm Wrench. Please note that in some applications additional adapters may also be required. Wiring Schematic Red: 12v Constant Source (+) White: 12v Ignition Switched Source (+) Orange: 12v Headlight Switched Source (+) Black: Vehicle/Engine Ground (-) TOOLS & ACCESSORIES NOT INCLUDED OPTIONAL ADD-ONS AND ADAPTERS SOLD SEPARATELY AT GLOWSHIFT.COM • Safety Glasses & Gloves • Assorted Wrenches • Socket Set • Flat Head Screwdriver • Phillips Screwdriver • Center Punch • Drill & Drill Bits • Tap Handle • Multi-Meter/Test Light • Wire Strippers & Crimper • Shop Vacuum • 3 or 4 Gauge Wiring Kit • MAP Line Boost T-Fitting Adapter • Expandable Circuits • 1/8-27 NPT Drill and Tap Set • HPOP Gauge Wiring Harness • 7.3L Fuel Pressure Adapter • 6.0L Fuel Pressure Adapter • Pen Magnet • Panel Pop Tool • Cutting Oil • Pick Tool • Zip Ties • Grommet • Drain Pan • Teflon Tape • Wire Connectors • Anti-Seize • Transmission Fluid CHECK OUT THE FULL INSTALL VIDEO FOR THIS POWER STROKE: GLOWSHIFT.COM/60FORD GLOWSHIFT.COM/73FORD

1999-2007 INSTALLATION GUIDE 1 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE Boost Gauge Installation SECTION 1 PREPARING THE INSTALLATION • Check that you have all parts required for installation, and that the engine is cool. • Open the hood and locate the truck's batteries. Using a wrench, disconnect the negative terminal of each battery to ensure there is no power running through the truck during the installation. Note: When it comes time to wire and connect the gauges to their power source, you will be able to reconnect the negative terminals on the batteries. Note: If you are installing a MaxTow Boost Gauge, you will be installing an electronic Boost Pressure Sensor and Harness instead of the Boost Line and Ferrule Fittings. 1. Remove the engine cover on 1999-2003 trucks using a 13mm socket. 2. Below are recommended ways for installation. (Please choose the one that best suits your specific needs.) A. T-FITTING INSTALL (7.3 and 6.0) 1. Locate the MAP line and cut it in half using cutters. Now that you have the MAP line cut, place hose clamps over the cut lines and insert the T-fitting into both cut ends. 2. Using a flat-head screwdriver, tighten the included hose clamps to ensure a secure fit with no leaks from the MAP line. 3. Take the included brass compression fittings and wrap the 1/8-NPT male thread with Teflon tape to ensure a leak-free connection. Insert the included boost hose into the thread connected to the T-fitting with a 12mm wrench and an 11mm wrench. Using a 3/8 wrench, tighten the compression fittings until the line is snug. Note: Do not overtighten. 4. Once the boost hose is connected, run the hose along the firewall to the driver side of the engine bay and secure any excess hose using Zip Ties to ensure there is no contact with any direct heat source or moving parts. A1b. A1a. A3. A4. 7.3 PICTURED 7.3 PICTURED 7.3 PICTURED 6.0 PICTURED PROPER ORIENTATION

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 2 FORD SUPER DUTY 7.3/6.0 POWER STROKE B. INTAKE AIR HEATER PLUG INSTALL (7.3 Only) 1. Locate the Intake Air Heater (IAH) on the cold side of the intake manifold on the passenger side of the vehicle. 2. The wire that runs from the IAH down to the solenoid is the main power wire for the IAH element. Using a 13mm wrench, remove the nut and washer from the solenoid and disconnect the power wire from the solenoid. Note: Ensure that the additional power feed wire that is not connected to the IAH is installed back onto the solenoid and secured with the washer and nut. 3. Using a 10mm wrench, remove the captured nut and power wire from the stud on the IAH. Once this has been removed, you can remove the power wire from the IAH. 4. Remove the ceramic insulator from the IAH and set the stud aside. Then, remove the ground wire from the IAH. 5. The ground wire coming from the IAH connects to a grounding location under the intake manifold. Use a 13mm wrench to remove the retaining nut and disconnect the ground wire. 6. Use a 1” wrench to remove the IAH assembly from the intake manifold. 7. Thread and tighten the IAH Delete Plug into the intake manifold using a 1 1/16” wrench. Note: Do not overtighten. 8. Take the included brass compression fittings and wrap the 1/8-NPT male thread with Teflon tape to ensure a leakfree connection. Insert the included boost hose into the thread connected to the T-fitting with a 12mm wrench and an 11mm wrench. Using a 3/8 wrench, tighten the compression fittings until the line is snug. (Reference diagram on page 1) Note: Do not over tighten. 9. Route the boost line to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. C. DRILL & TAP SPYDER (7.3 Only) 1. Using an 11mm deep socket, remove the intercooler pipe. 2. Place a vacuum inside the intake spyder to prevent shavings from entering the intake during the drill and tap process. 3. Mark the planned drilling location with a center punch. Starting with a 1/8” drill bit, drill a pilot hole into the manifold and gradually step up in drill bit sizes until size R is reached. 4. Now that the hole is drilled to size R, clean the manifold with a vacuum to ensure no shavings are in the manifold. B6. B7. B8. C3.

1999-2007 INSTALLATION GUIDE 3 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE 5. Tap the hole using a 1/8-27 NPT tap and clean the manifold with a vacuum to remove all shavings. 6. Take the included brass compression fittings and wrap the 1/8-NPT male thread with Teflon tape to ensure a leakfree connection. Insert the included boost hose into the thread connected to the T-fitting with a 12mm wrench and an 11mm wrench. Using a 3/8 wrench, tighten the compression fittings until the line is snug. (Reference diagram on page 1) Note: Do not over tighten. 7. Route the boost line to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. 8. Reinstall the intercooler pipe. D. DRILL & TAP INTAKE ELBOW (6.0 Only) 1. Using an 11mm deep socket, loosen the intercooler coupler and slide the pipe out of the way. 2. Using 8mm and 10mm sockets, remove the intake elbow. 3. Mark the drilling location with a center punch. Using a 1/8” drill bit, drill a pilot hole and gradually step up in drill bit sizes until size R is reached. Tap the hole using a 1/8-27 NPT Tap. 4. Clean the shavings from the intake elbow. 5. Take the included brass compression fittings and wrap the 1/8-NPT male thread with Teflon tape to ensure a leakfree connection. Insert the included boost hose into the thread connected to the T-fitting with a 12mm wrench and an 11mm wrench. Using a 3/8 wrench, tighten the compression fittings until the line is snug. (Reference diagram on page 1) Note: Do not over tighten. 6. Re-install the intake elbow using the 8mm and 10mm sockets. 7. Route the boost line to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. D2. C6. D5. D6.

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 4 FORD SUPER DUTY 7.3/6.0 POWER STROKE Pyrometer EGT Gauge Installation SECTION 2 Optional: Safely jack up the truck for easier access to the driver's side exhaust manifold. 1. Take necessary safety precautions to confirm that the exhaust is sufficiently cool during this process. 2. Using a center punch, mark the location where you are going to drill a hole for the EGT probe on the manifold. The hole's location should be on the bottom side of the driver's side exhaust manifold before the up-pipe leading to the turbo. 3. Starting with a 1/8” drill bit, drill a pilot hole into the exhaust manifold. Continue increasing the size of the pilot hole using various drill bits until you reach size R. 4. Using cutting oil, tap the hole to 1/8-27 NPT. 5. Ensure all shavings are out of the manifold by periodically using a vacuum and a pen magnet to remove them. Warning: Failure to remove metal shavings can result in possible engine damage. 6. Apply anti-seize to the threads of the EGT ferrule fitting and thread the fitting into the exhaust manifold. Tighten the fitting with a 14mm wrench. 7. Install the gauge's EGT Sensor into the Ferrule Fitting Adapter, ensuring the sensor is positioned approximately halfway into the manifold. Tighten using a 14mm wrench Note: Do not overtighten the ferrule fitting. 8. Plug the EGT Sensor Harness into the EGT Sensor. 9. Route the EGT Sensor Harness to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. Optional: Lower the vehicle if it was raised. 2. 3. 7. 7. 6.0 PICTURED 6.0 PICTURED 7.3 PICTURED 7.3 PICTURED

1999-2007 INSTALLATION GUIDE 5 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE Transmission Temp Gauge Installation SECTION 3 Note: If you are installing a MaxTow Transmission Temperature Gauge, the connectors are already attached to the Transmission Temperature Sensor Harness and can simply be plugged into the Transmission Temperature Sensor before routing the wire to the firewall. Optional: Safely jack up the truck for easier access to the driver's side of the transmission. 1. Wrap the Transmission Temperature Sensor threads with Te on tape. 2. Using an 11mm deep socket, remove the transmission test port located on the driver's side above the second transmission pan bolt from the front of the truck. Note: Have a drain pan available to catch any leaking fluid. 3. Thread the sensor into the test port and tighten using a 14mm wrench. Note: Do not overtighten. 4. Attach the female silver connector and the longer rubber cover to one end of the green wire from the Gauge Wiring Harness and connect it to the white wire from the sensor. 5. Attach the male silver connector and shorter rubber cover to the end of a wire from the Gauge Wiring Kit and connect to the black wire from the sensor. 6. Route the Transmission Temperature Sensor wires to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. Optional: Lower the vehicle if it was raised. 7. Connect the Transmission Temperature Sensor ground wire to a reliable grounding source in the engine bay. 8. Top off the transmission fluid according to manufacturer specifications if needed. 3. 2. 5.

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 6 FORD SUPER DUTY 7.3/6.0 POWER STROKE SECTION 4 Fuel Pressure Gauge Installation A. 7.3 Installation 1. Thread the Fuel Pressure Sensor into the 7.3L Power Stroke Fuel Pressure Sensor Adapter using a 14mm wrench and a 22mm wrench. 2. Place a rag on the intake manifold to catch any draining fuel from the fuel filter housing. 3. Drain the fuel using the yellow drain valve. 4. Use a 3/16” Allen key to remove the plug from the back side of the fuel filter housing. Note: Be careful not to strip the plug. 5. Thread the sensor and adapter into the fuel filter housing and tighten with a 14mm wrench. Warning: Remove the rag from the manifold. 6. Plug the sensor harness into the sensor. 7. Route the Fuel Pressure Sensor Harness to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. Note: Once the batteries are reconnected, cycle the key five times to prime the system and then start the engine. Be sure to check for leaks. A5. A4. A6.

1999-2007 INSTALLATION GUIDE 7 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE B. 6.0 Installation Note: The intercooler pipe was removed to gain access for this manual's photography. This is NOT a required step for the install. 1. Thread the Fuel Pressure Sensor into the 6.0L Power Stroke Fuel Pressure Sensor Adapter using a 14mm wrench and a 22mm wrench. 2. Have a drain pan ready to catch any fuel that may drip out. 3. Using a 6mm Allen key, remove the factory plug from the front of the fuel filter housing. 4. Tighten the adapter into the fuel filter housing using a 22mm wrench. Note: Do not overtighten the adapter. 5. Plug the sensor harness into the sensor. 6. Route the Fuel Pressure Sensor Harness to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. Note: Once the batteries are reconnected, cycle the key five times to prime the system and then start the engine. Be sure to check for leaks. B3a. B6. B4. B3b.

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 8 FORD SUPER DUTY 7.3/6.0 POWER STROKE HPOP Installation 1. Locate the Injection Control Pressure (ICP) Sensor. For the '99-'03 7.3L, it is located next to the driver side valve cover. For the '03 and early '04 6.0L, it is located beneath the turbo, which can be accessed from under the truck on the driver side. For the late '04-'07 6.0L, it is located on the passenger side valve cover. 2. Unclip the factory harness connector and plug in the HPOP Gauge Wiring Harness pigtail to both ends. 3. Route the HPOP Pressure Sensor Signal Wire to an opening on the firewall on the driver's side of the engine bay and use Zip Ties to secure. Make sure there is no contact with any direct heat source or moving parts. Connect the Green signal wire from the gauge to the Green signal wire from the harness. 4. Connect the Black signal wire from the gauge to the Black signal wire from the harness. 5. If you are not installing the High Pressure Oil Pressure HPOP Gauge Wiring Harness, connect the green signal wire from the gauge to the Dark Blue with Light Green tracer of the ICP Sensor Harness. 6. Connect the Black ground wire from the gauge to the Gray with Red tracer of the ICP sensor harness. SECTION 5 2a. 2b. 2c. 7.3 PICTURED 7.3 PICTURED 6.0 PICTURED OPtional HPOP Gauge Wiring Harness

1999-2007 INSTALLATION GUIDE 9 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE Installing the Pillar Pod SECTION 6 1. Remove the Factory A-Pillar Trim. A. Non-Grab Handle Installation ('99–'02) 1. Carefully remove the factory trim from the truck by pulling and releasing the spring clips. Note: This gauge pod mounts directly on top of your truck's A-pillar using the supplied push-in clips and is not a complete replacement. B. Grab Handle Installation ('03–'07) 1. Using a flat head screwdriver, remove the bolt covers on the grab handle. 2. Remove the 4 bolts on the grab handle using a 10mm socket. 3. Remove the A-pillar by releasing the spring clips. 4. Using a #2 Phillips Head Screwdriver, remove the 2 screws securing the handle from the backside of the A-pillar. Both 1. Place the triple pillar pod overtop of the removed factory trim. 2. Mark and drill (4) 7/32” holes and secure with the flush mount fasteners. 3. Mark and drill holes using a step bit for the wiring to pass through the factory trim. 4. Wrap Teflon tape around the brass fitting on the back of the Boost Gauge, then attach the female brass fitting for the boost line using a 13mm wrench. Note: Do not overtighten. 5. Feed the wires from each gauge into the pillar pod. 6. Insert each gauge into the pod. 7. If you are using the optional 3 or 4 Gauge Wiring Kit, attach all of the wires together. 8. Connect all of the yellow wires using a splice connector. 9. Connect all of the red wires using a splice connector. A1. B2. 3.

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 10 FORD SUPER DUTY 7.3/6.0 POWER STROKE 10. 19. 12. 10. Connect all of the orange wires using a splice connector. This enables the dimming function that will lower the brightness of your gauges 30% for easier viewing when driving at night. 11. Connect all of the black wires using a splice connector. 12. Secure all wires with Zip Ties. 13. Route the wires through the firewall and into the cab of the truck, keeping clear of any moving parts. Note: You may need to drill a hole in the firewall if there isn't one already. It is important to use a grommet on the hole to ensure the wires are not sliced or cut on the firewall. 14. Insert the boost line into the Ferrule Fitting Adapter, thread onto the back of the gauge and tighten with a 3/8” Wrench. (Refer to diagram below) Note: Do not overtighten the Ferrule Fitting. 15. Plug the EGT Sensor Harness into the back of the EGT Gauge. (If used) 16. Splice the green signal wire from the Transmission Temperature Gauge to the green signal wire from the sensor. (If used) 17. Plug the Fuel Pressure Sensor Harness into the back of the Fuel Pressure Gauge. (If used) 18. Splice the signal wire from the ICP Sensor to the green signal wire from the High Pressure Oil Pressure Gauge. (If used) 19. Mount the pillar pod and factory trim assembly to the truck cab A-pillar, securing it with the factory spring clips. Note: For 2003-2007 trucks the grab handle, bolts and screws will no longer be used. PROPER ORIENTATION

1999-2007 INSTALLATION GUIDE 11 GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved FORD SUPER DUTY 7.3/6.0 POWER STROKE A. '99–'03 Installation 1. Attach the Mini Expandable circuits to both the yellow wire and the red wire. 2. Remove the fuse from fuse location 4. Plug the fuse into the open section of the expandable circuit for the yellow wire and reinstall in the fuse box. Note: Be sure that 2 fuses are installed in the expandable circuit. 3. Remove the fuse from fuse location 19. Plug the fuse into the open section of the expandable circuit for the red wire and reinstall in the fuse box. Note: Be sure that 2 fuses are installed in the expandable circuit. 4. Using a panel pop tool, gently remove the headlight switch from the dash. 5. Splice the orange wire to the red wire with the yellow tracer at the headlight switch. 6. Reinstall the headlight switch. 7. Connect the black wire to a reliable, clean and unpainted ground source such as the mounting bolt located on the right side of the fuse box. 8. Secure any excess wiring with Zip Ties. 9. Reconnect the negative cables of both batteries by tightening with a 13mm wrench. 10. Power up the truck to see if the gauges are functioning properly and check for any leaks or loose sensor connections. With the vehicle running, cycle through the gears to help the transmission fluid circulate through the transmission (if the transmission temperature gauge is installed). Top off any fluids if necessary. 11. Press the Color Change Button on the gauges to ensure they are working correctly. Note: MaxTow Gauges do not change colors. The button allows you to change the 3 Daytime and 3 Nighttime Brightness Levels. 12. Test drive your vehicle to ensure all gauges are functioning properly. Note: The boost gauge will only read while driving. Connect to Power SECTION 7 A5. A9. Fuse 4 (A2.) Fuse 19 (A3.)

1999-2007 INSTALLATION GUIDE GlowShift.com © GlowShift Gauges, LLC | All Rights Reserved 12 FORD SUPER DUTY 7.3/6.0 POWER STROKE B. '04–'07 Installation 1. Attach Mini Expandable circuits to both the yellow wire and the red wire. 2. Remove the fuse from fuse location 13. Plug the fuse into the open section of the expandable circuit for the yellow wire and reinstall in the fuse box. Note: Be sure that 2 fuses are installed in the expandable circuit. 3. Remove the fuse from fuse location 45. Plug the fuse into the open section of the expandable circuit for the red wire and reinstall in the fuse box. Note: Be sure that 2 fuses are installed in the expandable circuit. 4. Using a panel pop tool, gently remove the headlight switch from the dash. 5. Splice the orange wire to the red wire with the yellow tracer at the headlight switch. 6. Reinstall the headlight switch. 7. Connect the black wire to a reliable, clean and unpainted ground source such as the mounting bolt located on the right side of the fuse box. 8. Secure any excess wiring with Zip Ties. 9. Reconnect the negative cables of both batteries by tightening with a 13mm wrench. 10. Power up the truck to see if the gauges are functioning properly and check for any leaks or loose sensor connections. With the vehicle running, cycle through the gears to help the transmission fluid circulate through the transmission (if the transmission temperature gauge is installed). Top off any fluids if necessary. 11. Press the Color Change Button on the gauges to ensure they are working correctly. Note: MaxTow Gauges do not change colors. The button allows you to change the 3 Daytime and 3 Nighttime Brightness Levels. 12. Test drive your vehicle to ensure all gauges are functioning properly. Note: The Boost Gauge will only read while driving. B5. B7. B10. Fuse 13 (B2.) Fuse 45 (B3.)

POWER STROKE Any Questions? Let us Help! 1.888.GS.GAUGE MON-FRI 9AM-5:30PM ESt

ADDRESS: 444 COMMERCE LANE SUITE A • WEST BERLIN, NJ 08091 EMAIL: TECHSUPPORT@GLOWSHIFTGAUGES.COM PHONE: 1.888.GS.GAUGE WEB: WWW.GLOWSHIFT.COM 9-21

RkJQdWJsaXNoZXIy MTIxODAy