There are still over 2 Million Power Stroke Diesel
trucks on the road today!
1999 - 2003 Ford F-Series Super Duty
Phoenix Module Installation Instructions
Before proceeding any further,
Open the hood and locate the computer (PCM) harness connector. It is located on the driver's side firewall, beneath the brake master cylinder and next to the fender. The connector is rectangle shaped, approx. 1" x 6" with a 10mm bolt in the center. Using a 10 mm socket, remove the connector from the PCM. The bolt is attached to the connector and DOES NOT come out.
From beneath the dash locate the PCM. It is mounted next the parking brake assembly. Remove the two (2) 9/32" bolts that hold the PCM case to the mounting bracket and set them aside. Grasp the rear of the PCM case, shift it to the right (towards the brake pedal), and firmly pull away from the firewall.

On manual transmission equipped vehicles, the clutch pedal may cause some interference. In order to help simplify the removal of the PCM, it is recommended that you have someone assist you by depressing the clutch pedal while you remove the PCM case.
Remove the PCM from the case. Remove and save the gold colored ground tab from the plastic case. Also remove and save the black plastic cap from the rear of the PCM.
Most PCMs will have a coating of clear silicone covering the connector. This coating MUST be throughly removed in order for the module to make proper contact with the PCM circuit board.
It is recommended that you open the PCM case by removing the 6 case bolts with a 7/32" socket. This allows complete access to BOTH sides of the connector to ensure that it is clean. The PCM circuit board is sealed and is quite robust. However, to avoid damage from static discharge, it is recommended that you avoid contact with any of the internal components wherever possible. Use the provided Scotch-BriteŽ pad to clear away the silicone. Acetone (nail polish remover) helps to clean the connector.

(Note: DO NOT USE CARB CLEANER, LACQUER THINNER, OR ANY OTHER AGGRESSIVE SOLVENT TO CLEAN THE PCM CONNECTOR!! It will damagethe fiberglass resin on the circuit board and permanent damage to the PCM can result!!)

BOTH sides of the connector must be cleaned thoroughly, but avoid being too aggressive. If you are cleaning the connector and begin to see copper, you are cleaning too far. This may result in a poorly fitting or loose module.

Once completed, reassemble the PCM case BEFORE installing the module onto the connector. This ensures that you do not accidentally install the module upside down.

Note: Failure to properly clean the connector may cause the vehicle not to start and/or may damage either the module or the PCM. Any module that has failed due to improper installation WILL NOT be covered under warranty.

Note: 98% of all tech calls involving a No-Start condition can usually be traced back to poorly cleaned contacts. Please take your time and clean the PCM connector thoroughly as it will save you unwanted headaches down the road.
Fasten the module to the PCM using fiberglass duct or packaging tape. Reinsert the PCM in the case, being careful not to crimp or cut the switch wires between the case and the PCM. Install the complete assembly back underneath the dashboard. The label on the PCM connector should be facing the fender. Reconnect the PCM harness connector. Save the case bolts, ground tab and plastic cap in case you should ever need to remove the module.

Note: DO NOT attempt to reinsert the PCM case bolts as this will put undesired pressure on the module and may cause a connection issue. If you wish to mount the PCM case using the bolts, it is recommended that you notch the rear of the plastic case to match the opening for the service port of the ECM. This will ensure that no pressure is placed on the module and avoid any connection issues.
Turn on the ignition key and check for proper operation of the "Wait to Start" or "Glow Plug" light. If no light appears, TURN OFF the ignition key, remove the module and re-clean the edge connector. Once the light operation is verified, start the vehicle and verify that it appears to be operating correctly.

NOTE:The "Check Engine" light may blink very quickly, appearing as little more than a slight flicker. This is an acceptable indication of normal function.
If equipped, mount the rotary switch in a convenient location, taking care to ensure that the lock tab for the switch is inserted in the hole that corresponds to the number of positions programmed on the module.
Now make sure your teeth are brushed. Once you start driving, you'll be smiling like crazy!
Ford 7.3L
Power StrokeŽ Diesel