Bully Dog 4-Bank 6-Position Chip User Manual

INSTALLATION MANUAL

4BANK 6POSITION CHIP

Vehicle Application Part#

F250-F350 7.3L ’94-’97 Automatic Transmission Ford Power Stroke 41611

F250-F350 7.3L ’94-’97 Standard Transmission Ford Power Stroke 41612

F250-F350 7.3L Early ‘99 Automatic Transmission Ford Power Stroke 41613

F250-F350 7.3L Early ’99 Standard Transmission Ford Power Stroke 41614

F250-F350 7.3L ’99.5-’01 Automatic Transmission Ford Power Stroke 41615

F250-F350 7.3L ’99.5-’01 Standard Transmission Ford Power Stroke 41616

F250-F350 7.3L ’02-’03 Automatic Transmission Ford Power Stroke 41617

F250-F350 7.3L ’02-’03 Standard Transmission Ford Power Stroke 41618

TABLE OF CONTENTS

INTRODUCTION/BILL OF MATERIALS ..................................................................PG 2

INSTALLATION STEPS...................................................................................PGS 49

94-’97 Installation

Removal of ECU..................................................................................................Pg 4

ECU Disassemble................................................................................................Pg 5

Installing 6 Position Chip ...................................................................................Pg 6

Installing Switch................................................................................................Pg 7

Early ’99-‘03 Installation

Removal of ECU....................................................................................................Pg 8

ECU Disassemble ...............................................................................................Pg 9

Installing 6 Position Chip..................................................................................Pg 10

Installing Switch ..............................................................................................Pg 11

Switch Operation.........................................................................................Pg 12

TROUBLESHOOTING .......................................................................................PG 13

WARRANTY & DISCLAIMER .............................................................................PG 14

TABLE OF CONTENTS

TROUBLESHOOTING:

Please review the Troubleshooting section on page 13 before
calling technical support to cover most common issues.Techni­cal support is available by calling 866-bullydog (866-285-

5936).

1

INTRODUCTION

Welcome to the world of increased power, performance and economy brought to you by the leader in perfor­mance, Bully Dog Technologies. This set of instructions outlines how to install and operate the 6 Position Chip
for the 7.3L Ford Power Stroke. The 6 Position Chips have been specially designed by the engineers at Bully Dog
to add additional horsepower and economy to the 7.3L Power Stroke.

Note: This instruction set and the included 6 Position chip are made for the ’94-’03 7.3L Ford Power Stroke. This chip
will not work on any other vehicle other than the stated make, model and year. Officially there were no ’98 model Power
Stroke vehicles produced by Ford, these vehicles are referred to as early ’99 vehicles.

IMPORTANT: Performance Chips must always be removed before taking the vehicle in for any kind of service, as it
may interfere with diagnostic tools.

IMPORTANT: DISCONNECT THE BATTERY BEFORE YOU BEGIN INSTALLATION

BILL OF MATERIALS

1. 6 Position Chip

2. 6 Position Switch

INTrOduCTION

TOOLS NEEDED

5.5mm Wrench or Socket
7mm Wrench or Socket

10mm Wrench or Socket
13mm Wrench or Socket

5/16” Allen Wrench

Sharp Knife or Razor Blade

Drill & 13/32” Drill Bit

Scotch Bright Pad

1.

2

INSTALLATION STEPS

‘94’97 7.3L 6 POSITION CHIP

Ford ECU

10mm Nut

10mm Bolt

10mm Nut

(Firewall)

EARLY ’99’03 7.3L 6 POSITION CHIP

7mm Bolts

10mm Bolt

6 Position Chip

Ford ECU

6 Position Switch

6 Position Chip

6 Position Switch

(Firewall)

3

REMOVING THE ECU FROM THE ENGINE BAY FIREWALL ‘94‘97

In these steps you will remove the ECU from the firewall.

INSTALLATION STEPS

IMPORTANT: The steps
on this page are for
’94-’97 model vehicles.
If your vehicle is not a
’94-’97 skip the steps on
this page.

ECU

ECU on ‘94-’97 vehicles

1. Disconnect the battery.

2. Locate the back side of the ECU on the firewall closest to the wheel-well in the engine bay.

3. There is a 10mm bolt that needs to be removed from the back side of the ECU. The 10mm bolt is located in the center of the
housing.

4. Remove 10mm nuts that hold the ECU in place at the top and bottom of the ECU seal.

5. Slide the ECU out from the firewall.

10 MM Bolt

10 MM Bolt

ECU with Seal Removed

ECU pulled out half way

4