Fuel pump wiring upgrades are ALMOST ALWAYS NEEDED or at least very helpful on these trucks! This is a post to help guys understand these wiring upgrades that are needed, and properly sizing wiring for the distance that it is run over. Running new thicker wire from the plug on the fuel pump hat, to the stock relay does the SAME THING as a "Hotwire kit" and is usually all that needs done on these trucks to get much more consistent fuel flow and keep things from melting! simple 10ga wire from relay back will cover most any single pump up to 800whp
-WIRING UPGRADES....Again the big weakness of these trucks is the pump wiring! It's BARELY enough for a stock pump, especially on 2.2 trucks with the higher flow pump, as my 2.2 trucks fuel pump plug was just slightly melted at only 97k miles!! Upgrading the wiring to something that's thicker and up to the task does EXACTLY what an overpriced “hotwire kit” does! No need to rerun your entire fuel pump wiring setup, new trigger, new relay, etc.
-OHMS LAW AND AWG....This is an electrical law that tells us that the longer the wire is, and the thinner the wire is, the more the current draw will go up, meaning the heat and or resistance will go up, and voltage will drop! This means not only will your pump not flow to its full potential, but it will also melt connectors and could lead to fires!! Select the correct AWG gauge of wire and youll be fine. Chart posted below in the picture of gauge versus distance also
-HOW TO FIND WHAT WIRE GAUGE YOU NEED...Almost every major brand of pump will have a chart online showing the amps drawn at which flow rate and voltage. As an example... ive listed some common pump models amperage draw, all values below are at 12v and 60psi of flow. This is the sustained amperage, and they can easily draw more under high stress, more heat, etc meaning thicker wire than recommended is always the better way to do it. 10ga is usually the go to for any single pump
-Walbro 255... 10.6 amps each
-Walbro 340... 12.5 amps each
-Walbro 450... 15.2amps each
-Walbro 525 hellcat... 18.5amps each
-DW 200, 255lph... 10.4 amps each
-DW 300, 340lph...12.3 amps each
-DW 400, 415lph... 17.7 amps each
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