Upgrading Your Ford F250: New Computer, New Fuel Tank

The Powertrain Control Module (PCM) is the brain of your Ford F-250, housing the central computer and controlling everything. Changing the PCM is easier than you might think and could save you money. If you have replaced your fuel tank, you will need to reprogramme your F-250 to adjust for the new tank size. This can be done using a tool such as the IDS.

Removing the fuel tank

This step requires siphoning gas and using a car jack and several stands. You will also be spending a lot of time underneath your vehicle and you will need to remove all lines that connect the fuel tank to the truck itself. The biggest difficulty with this option is that some of the connections might be very rusty and tough to loosen.

Tools required:

• Clear hose and air pump for siphoning gas
• New fuel pump assembly
• Car jack and four stands
• Flathead screwdriver
• 3/8" fuel line disconnect tool (useful but not necessary)

Step 1: Remove fuel from your tank

Before removing your fuel tank, you will need to be sure it is empty — or close to empty. In order to do this, you will need to siphon the gas out using a clear hose and air pump.

Step 2: Elevate your truck

In order to safely work beneath your F-150, your vehicle will need to be propped at least 18 inches above the ground. Use a standard jack and place it in the grooves along the frame of your truck. For trucks that are already lifted, you may have enough room to work without having to jack up your truck.

Step 3: Remove the heat shield

Once your truck is safely and securely raised, grab your impact wrench and crawl under the truck. You will find that the heat shield is protecting the fuel pump. You will also notice two sets of bolts. One set holds the heat shield in place. The second set holds the fuel tank in place. You first want to locate those that hold the heat shield. They will be aligned with the heat shield strap.

Be careful not to remove the bolts for the tank straps before removing the heat shield. After removing the bolts, the heat shield will start to drop as you remove it. Place your knee against it so it doesn't fall on you as you wiggle it free. Once it is free, put it aside.

Step 4: Remove the fuel tank

Grab two floor jacks and place them underneath the fuel tank. You will need these to support the fuel tank as you remove its bolts. Be sure that the jacks are raised just enough to support the tank. It's also a good idea to insert some soft padding between the jack stand and the tank to prevent damage.

Once again, use your impact wrench to remove the four exceptionally long bolts (13mm) from the fuel tank. Once both straps are loosened, lower the straps and twist them off. Don't force them or you will wind up ruining the mounting point. Set the two straps and the bolts to the side.

Now your fuel tank should be supported only by the jack stands. Ask somebody to slowly lower the stands while you hold the fuel tank. The front end won't drop right away because it is connected to the fuel fill line. You will need a 1/4 inch hex socket to remove this connection.

Once the fuel fill line is disconnected, your assistant can lower the jack stands further and you should be able to pull the fuel tank out from under the truck.

Disconnecting the battery

Locate the battery: The battery is located in the engine compartment of your F-250. It is usually found near the front of the engine, but the exact location may vary depending on the model year and configuration.

Gather the necessary tools: You will need a few tools to disconnect the battery safely. These include a pair of gloves, eye protection, and a wrench or socket that fits the battery terminal bolts. It is also recommended to have a bag of grease or vaseline nearby to prevent battery corrosion.

Prepare the worksite: Park your F-250 on a level surface and engage the parking brake. Make sure the engine is off, and if possible, cover the surrounding area with a tarp or cardboard to protect it from any potential acid spills.

Loosen the battery terminals: Put on your gloves and eye protection. Identify the negative (-) and positive (+) terminals on the battery. Using your wrench or socket, loosen the terminal bolts in a counter-clockwise direction. Do not remove the bolts entirely yet; just loosen them enough so that you can wiggle the terminals.

Disconnect the negative terminal first: This is an important safety precaution. Always disconnect the negative terminal before the positive terminal to reduce the risk of sparks or short circuits. Once the negative terminal bolt is loose, carefully remove the terminal from the battery post. You may need to wiggle it gently to break the seal of any corrosion that has built up.

Move the negative terminal away from the battery: Place the negative terminal to the side, making sure it does not touch any metal parts of the vehicle. You can wrap the terminal in a cloth or secure it with tape to prevent accidental contact.

Disconnect the positive terminal: Now, you can safely disconnect the positive terminal. Loosen the positive terminal bolt and remove it from the battery post. Again, wiggle it gently if necessary to break any corrosion seal.

Apply grease or vaseline: With both terminals disconnected, take this opportunity to apply a thin layer of grease or vaseline to the battery posts. This will help prevent corrosion and ensure a better connection when you reinstall the battery.

Store the battery safely: If you are not immediately reconnecting the battery, make sure to store it in a safe place. Keep the battery upright and away from open flames or sparks. Do not place metal objects on top of the battery, as this could create a short circuit.

By following these steps, you will be able to safely disconnect the battery on your Ford F-250. Remember to work carefully and take the necessary precautions to protect yourself and your vehicle.

Switching the modules

Before you switch the modules, you will need to locate the PCM and record the module and Strategy Code numbers. The PCM is the brain of your Super Duty that houses the central computer and controls everything. The Strategy Codes are located on the PCM connector.

Once you have the PCM and Strategy Code numbers, you can purchase the new module. It is important to compare the new module with the existing one before installing it. The connectors and mounting locations should match. Most places will not accept a return if the module has already been plugged in.

Now, disconnect the battery cable from the negative side of the battery. Then, unbolt and disconnect the existing module. Compare it one more time before installing the new module.

There you have it! You have successfully switched the modules in your Ford F-250.

Replacing the fuel pump

The fuel pump is responsible for delivering gas from the fuel tank to the fuel injectors. It is important to replace the fuel pump when issues such as stalling, surging, or failure to start are observed, as these could indicate that the pump is failing. A whining noise from the tank area may also be a symptom of a failing fuel pump.

Firstly, disconnect the battery to reduce the chance of a fire. If the pump is inside the fuel tank, there will usually be an access cover that needs to be removed. With the cover off, the technician can replace the pump and pre-pump filter screen. In some cases, fuel will need to be drained before removing the access panel.

When the pump is located outside the tank, the process is slightly different. The mechanic will disconnect the fuel lines, remove the pump, and install the new one. Once the new pump is in place, another check will be done to ensure there are no fuel leaks and that the problem is solved.

It is recommended that fuel filters are replaced at the same time as the fuel pump. On some vehicles, the fuel pump relay is known to fail, so it is good practice to replace the relay when the pump is replaced.

Working with the fuel system is dangerous, so it is important to take all precautions against starting a fire. After the repair is done, be on the lookout for fuel leaks or odors. If you see or smell gasoline, do not start or drive the car, and do not park inside your house or under a covered structure. Have the car towed to a shop for inspection and repair.

Ford F-250 Fuel Pump Replacement

The average cost for a Ford F-250 Super Duty Fuel Pump Replacement is between $1,271 and $1,425. Labor costs are estimated between $166 and $209, while parts are priced between $1,105 and $1,216. This range does not include taxes and fees and does not factor in your unique location. Related repairs may also be needed.

Reprogramming the PCM

Step 1: Locate the PCM and Record the Module and Strategy Code Numbers

The PCM is located in your Ford F-250, and you need to find it and record the module and Strategy Code numbers. These codes are located on the PCM connector.

Step 2: Check the New Module

Purchase the new PCM module based on your findings. It is important to compare the new module with the existing one before installation. Ensure that the connectors and mounting locations match. Most retailers will not accept returns once the module has been plugged in, so be cautious.

Step 3: Disconnect the Battery Cable

Before proceeding, it is crucial to disconnect the battery cable from the negative side of the battery for safety reasons.

Step 4: Switch Modules

Now, it's time to remove the existing PCM module. Unbolt and disconnect it, but before installing the new module, compare them one more time to ensure they match.

Additional Notes:

• The PCM connector is protected by silicon, and cleaning the connector is essential for proper operation after installation.
• Certain solvents can damage the PCM, and reusing the PCM bolts is not recommended. In some cases, duct tape is used for reinsertion.
• It is advised to read the provided references and follow the PCM module manufacturer's recommendations.

By following these steps, you will be able to successfully reprogram the PCM in your Ford F-250, improving its performance and addressing any starting issues.

Frequently asked questions