TransferFlow dual tank controller failure remedy...
Years ago, before there was a Sportsmobile forum, there was a lot of traffic on the Yahoo Sportsmobile chat list. I saved one of those emails which discussed a method which described a method to bypass the TransferFlow controller for a dual tank setup if the controller failed and you really needed the fuel in the auxiliary tank. Here is that email:
The TransferFlow system is designed to satisfy an EPA requirement that your engine draw fuel only from the factory approved tank and emission systems (the ďmainĒ tank). The TransferFlow auxiliary tank complies by pumping its fuel into the filler pipe of the main tank when the TransferFlow computer senses that the main has dropped about 2 or 3 gallons below the auxiliary tank. The system is designed to simply shut down in the event of a failure with the computer controller, leaving you with whatever fuel is in the main, and no access to the auxiliary tank.
If the system fails, but you still have power to the control box connector (e.g. the fuses have not blown), you can manually turn on the transfer pump in the auxiliary tank and move its fuel into the main by by-passing the control box and jumping the power to the pump with a paperclip.
All you need is a small blade screwdriver, a paperclip, flashlight and a small magnifying glass.
1. Remove the 25-pin connector from the top of the control box located above the brake pedal using the small screwdriver.
2. All work is done at the connector and nothing in the control box.
3. The connector has two rows of contacts, the bottom of which has contact number 25 at the left. The numbers are stamped into the face of the connector and you might want to confirm the numbers with the magnifying glass.
4. Count back from 25 to the right to find contact number 21, and number 20 just to its right.
5. Insert the bent paper clip into connectors 21 and 20, making an electrical connection between them.
6. Leaving the paperclip in place, start the engine and the pump will begin transferring fuel. To check the operation, open the main fuel cap and, if itís working, you can hear the fuel going into the filler pipe. The pump transfers fuel at about 1/2 gallon per minute. Keep track of the time to measure the amount of fuel you wish to move. Also, itís not a good idea to let the pump run dry for a long time. Listening at the filler, you can hear when the fuel stops running.
I printed out that email and store it in our SMB along with a paper clip. Good insurance...
'01 Ford EB50p Quigley 4WD