Hypertech 41042 User Manual

IN-LINE POWER TUNING MODULE

2003-2004 Ford 6.0L Power Stroke
Super Duty F250/F350 & Excursion

Part #41042

STEP-BY-STEP INSTALLATION

INSTRUCTIONS

Revised 8.2.05

trademark of the Ford Motor Company

®

Part #593

© 2004-2005 Hypertech, Inc.

® Power Stroke is a registered

Kit Contains:

Hypertech Power Tuning Module
Wiring harness (connectors are marked for easy installation)
Hypertech rotary switch assembly
Hypertech mounting bracket (with module attached)
Hypertech switch plate (cable, switch with knob, connector/wire)
Small standard screwdriver
Installation and operation manual (instructions)
#10 Phillips-head screws (2 each)
Retaining plugs (2 each)
Tie-wraps (3 each)
One tube of Boss RTV sealer (0.5 oz.)

You will need the following:

Insulated adjustable wrench
(to tighten battery terminals and switch mounting nut)
Phillips-head screwdriver (for mounting bracket/module)
Standard (flat) screwdriver (for removing fuse panel)
10mm socket or nut-driver (for removing fuse block)
Drill and 1/8”, 3/8” and 1/2” drill bits
(for rotary switch installation)
Diagonal cutters (for removing tie-wrap excess)

2

PLEASE READ BEFORE INSTALLING THE

HYPERTECH IN-LINE POWER TUNING

MODULE FOR THE 6.0L POWER STROKE

Special instructions for the 6.0L Power Stroke

2003-2004 Ford Super Duty F250/F350 & Excursion

SPECIAL NOTE: Power Stroke engines built before 9/29/03
must be updated to the newest calibration level (B27.9 or
later) by an authorized Ford, Lincoln, or Mercury dealer.

Ford Motor Company’s Technical Service Bulletin No. 03-20-12
states the following…

“Some vehicles may exhibit various driveability conditions

listed below:

• Rough/rolling idle when the engine is warm.

• Rough/rolling idle and white smoke after hot restart.

• Lacks power after initial start-up.

• Cold idle kicker performance at warm ambient temps.

• U0306 codes after reprogramming.

• P2263 code set during extended idle.

• False P0196 codes.”

According to this Technical Service Bulletin (Article No. 03-20-12),
a PTM/TCM/FICM module calibration level update is available
for vehicles equipped with the 6.0L Power Stroke engine built
before 9/29/03 that exhibit one (1) of the above conditions.
Since this problem can occur on completely stock engines,
modifying these particular vehicles to make even more power
could worsen the problem.

WARRANTY any damage claims to the vehicle or

NOT
product if their in-line Power Tuning Module is installed on
any vehicle equipped with the 6.0L Power Stroke engine that
has not been updated to the newest calibration level (B27.9 or
later) by an authorized Ford, Lincoln, or Mercury dealership.

In addition, Ford Motor Company’s Technical Service Bulletin
No. 04-09-03

states the following:

For this reason, Hypertech WILL

“ Some vehicles equipped with the 6.0L diesel engine may exhibit

engine oil diluted with fuel (OIL LEVEL MAY APPEAR OVER
FULL), runs rough, and/or a lower power condition.”

For this reason, Hypertech WILL NOT WARRANTY any
damage claims to the vehicle or product if their in-line Power

uning Module is installed on any vehicle equipped with the

T

Power Stroke engine that exhibits any of these conditions.

6.0L

3

INSTALLATION INSTRUCTIONS

I. Disconnect the batteries

For specific instructions and precautionary steps regarding
recommendations for battery disconnection, refer to the
“Workshop Manual” for 2004 F250/350/450/550 vehicles,
published by Ford Motor Company. This manual also contains
battery-related precautionary steps regarding the Supplementary
Restraint System (SRS) or air bag system. Failure to read and
observe factory-recommended instructions may result in personal
injury or property damage.

disconnected and re-connected, some abnormal drive
symptoms may occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven to re-learn its
adaptive strategy.

1. Disconnect the secondary battery ground cable (passenger side
of the engine compartment).

2. Disconnect the primary battery ground cable on the driver’s
side of the engine compartment.

remove the retaining clip holding this cable to the battery cover.

3. Disconnect the primary battery positive cable (driver’s side of
the engine compartment).

4. Disconnect the secondary battery positive cable (passenger side
of the engine compartment).

NOTE: When the battery is

Note: You will also need to

5. Remove the battery cover from the primary battery (driver’s
side of the engine compartment) and set it aside. See Figure A.
When removing this cover, take care to ensure that the cables
around the cover are not damaged.

Battery On

Driver’s Side

Figure A

4

II. Locate the Powertrain Control Module (PCM)

6. See Figure B. Locate the powertrain control module (PCM).
It is located on the right side of the engine compartment beside
the primary battery. The PCM has three (3) connectors visible
at the front, facing the battery.

PCM with three (3)

connectors

Battery On

Driver’s Side

Figure B

7. See Figure C. Remove the center connector by pinching
the lever lock (small tab or tongue in the middle of the
connector, as shown) and pushing the lever away from the
PCM. The connector will slide out as you push the lever.

Lever lock

Figure C

5

8.See Figure D. The cable for the center connector lies in the
space between the battery and the power steering fluid
reservoir. Pull the connector and cable out from this space and
re-route it so that the connector is between the power steering
reservoir and the brake fluid reservoir.

Center connector

from PCM

Brake fluid

reservoir

III. Inspecting the Hypertech cable

9.The Hypertech
mounting bracket is

C3 connector

provided with the
in-line Power Tuning
Module and two (2)
mounting clips already
installed.

NOTE:
If these cables are
NOT already
connected as shown in
Figure E, identify
them and connect
them now.

Retaining plugs

C2 connector

Power steering

reservoir

Figure D

Figure E

10.

Manual Transmission
applications ONLY.

See Figure F.
Remove the retaining
plugs holding the clutch
fluid reservoir to the
bracket on the power
steering fluid reservoir
and lay the reservoir
out of the way

, prior

to beginning this step.

Power steering

reservoir

Clutch fluid

reservoir

Figure F

6