Installation Phases — Trader-01¶

Vehicle: 1996 F-250 Crew Cab System: Infinitybox NGX + Godzilla 7.3L + 6R140 Status: Planning Last Updated: 2026-02-01

Overview¶

This document breaks the full electrical install into manageable phases. Each phase can be completed in a work session, tested before moving on, and doesn't require tearing into multiple areas of the truck simultaneously.

Total estimated phases: 12 Dependencies: Each phase builds on the previous — don't skip ahead

Pre-Install Checklist¶

Before touching any wiring:

All Infinitybox components received and inspected
Address jumpers set on all POWERCELLs and inMOTION cells
STU Control Pack and TC Controller on hand
Dakota Digital VHX cluster on hand (or cluster decision final)
Core shopping list items received (Phase 1-2 minimum)
Vehicle accessible and stationary for duration
Battery disconnected
Fire extinguisher nearby

Address Jumper Settings (Do This First!)¶

Cell	Address	Jumper Config
Front POWERCELL	1	Remove pin 1 jumper
Rear POWERCELL	2	Remove pin 2 jumper
inMOTION #1 (Driver Front)	3	Remove pins 1 & 2
inMOTION #2 (Pass Front)	4	Remove pin 4 (or 1+3)
inMOTION #3 (Driver Rear)	5	Remove pins 1 & 4
inMOTION #4 (Pass Rear)	6	Remove pins 2 & 4

Reference: INFINITYBOX_REFERENCE.md

Phase 1: Demolition & Prep¶

Goal: Remove old wiring, prep mounting locations, establish routing paths

Duration: 1-2 sessions

Tasks¶

Document existing wiring with photos before removal
Label any wires being retained (gauges, sensors)
Remove old fuse box and associated wiring
Remove non-essential OEM harness sections
Clean engine bay of old wire routing hardware
Identify and mark firewall pass-through location
Clean interior routing paths (under carpet, kick panels)
Test-fit POWERCELL mounting locations
Test-fit MASTERCELL mounting location

Keep These OEM Items¶

Item	Reason
Fuel pump connector	Reuse at tank
Light sockets (if good)	May reuse in housings
Door jamb switches	May reuse for door ajar
Ignition cylinder wiring	Key switch input
Ground straps	Supplement with new

Tools Needed¶

Socket set, screwdrivers
Wire cutters, snips
Zip tie cutters
Plastic trim tools
Camera (documentation)
Masking tape + marker (labeling)

Exit Criteria¶

Engine bay clear of old harness
Interior routing paths accessible
Mounting locations confirmed
Photos documented

Phase 2: Power Distribution¶

Goal: Establish main power backbone — battery to distribution points

Duration: 1 session

Tasks¶

Wire Runs This Phase¶

Run	Gauge	From	To	Fuse
Starter feed	0 AWG	Battery +	Starter relay	None
Front PC feed	4 AWG	Battery +	Front PC location	150A ANL
Rear PC feed	4 AWG	Battery +	(staged)	100A ANL
STU feed	8 AWG	Battery +	STU location	60A ANL
Block ground	2 AWG	Battery -	Engine block	—
Frame ground	0 AWG	Battery -	Frame rail	—
Front PC ground	4 AWG	Battery -	Front PC location	—

Do NOT Connect Yet¶

Do not connect power to any cells
Do not install fuses
Verify all runs before energizing

Tools Needed¶

Cable crimper (hydraulic or hammer)
Heat gun
Wire strippers
Torque wrench (battery terminals)

Exit Criteria¶

All power cables routed and terminated
Ground points established
Fuse holders installed (fuses OUT)
Continuity tested on all runs

Phase 3: Firewall Penetration¶

Goal: Establish clean pass-through for all cab-to-engine wiring

Duration: 1 session

Tasks¶

Wires Through Firewall¶

Wire	Gauge	Direction	Purpose
CAN-H	18 AWG	Engine → Cab	POWERCELL to MASTERCELL
CAN-L	18 AWG	Engine → Cab	POWERCELL to MASTERCELL
CAN Shield	—	Engine → Cab	Ground at MASTERCELL only
Key-On Out	18 AWG	Cab → Engine	MASTERCELL to STU/PC
Crank Signal	18 AWG	Cab → Engine	MASTERCELL to starter relay
Tach	18 AWG	Engine → Cab	STU to cluster
Reverse	18 AWG	Engine → Cab	STU to MASTERCELL
Temp sender	18 AWG	Engine → Cab	To cluster (if needed)
Oil sender	18 AWG	Engine → Cab	To cluster (if needed)

Estimated: 10-15 wires through single grommet

Tools Needed¶

Hole saw or step bit
Deburring tool
Grommet
RTV sealant
Split loom
Fish tape or wire pull

Exit Criteria¶

Clean firewall penetration
All planned wires passed through
Weatherproof seal verified
Loom installed both sides

Phase 4: Front POWERCELL Installation¶

Goal: Mount front POWERCELL, connect power, verify CAN communication

Duration: 1 session

Tasks¶

Do NOT Connect Outputs Yet¶

This phase is power and CAN only — outputs connected in Phase 8.

Mounting Considerations¶

Minimum 2" from exhaust components
Above expected water line
Accessible for future service
CAN cable reaches firewall

Tools Needed¶

Drill, bits
Wrenches for mounting hardware
Torque wrench (power connections)
Multimeter

Exit Criteria¶

POWERCELL securely mounted
Power connected, fuse installed
Ground connected
CAN cable connected to firewall pass-through
Visual power-on test passed

Phase 5: MASTERCELL Installation¶

Goal: Mount MASTERCELL, establish CAN communication with front POWERCELL

Duration: 1 session

Tasks¶

First System Test¶

With MASTERCELL and front POWERCELL connected:

Key-on (or jumper key-on input)
Both cells should show communication LEDs
If inCODE available, connect and verify device list

Troubleshooting¶

Symptom	Check
No MASTERCELL LED	Power, ground, fuse
No POWERCELL LED	Power, ground, fuse, address jumper
No communication	CAN wiring, termination, address conflict

Tools Needed¶

Drill, bits (if mounting)
Zip ties, adhesive mounts
Multimeter
inCODE programmer (optional but helpful)

Exit Criteria¶

MASTERCELL mounted and powered
CAN communication verified
System ready for input wiring

Phase 6: Input Wiring (Switches to MASTERCELL)¶

Goal: Connect all switch inputs to MASTERCELL

Duration: 2-3 sessions

Session 6A: Column & Dash Switches¶

Session 6B: Auxiliary Switch Panel¶

Session 6C: Vehicle Status Inputs¶

Wire parking brake switch
Wire door ajar switches (4 doors)
(Or defer to inMOTION if handling door triggers)
Wire reverse signal from STU
Wire any other status inputs

Input Verification¶

After each switch is wired:

Use multimeter to verify continuity when switch activated
Verify no shorts to ground
Use inCODE (if available) to see input state change

Reference¶

MASTERCELL_INPUT_MAP.md — input assignments
SWITCH_PANEL_LAYOUT.md — switch locations

Tools Needed¶

Wire strippers
Crimpers (Deutsch, terminals)
Multimeter
Heat gun
Label maker

Exit Criteria¶

All inputs wired per MASTERCELL_INPUT_MAP
Each input tested for continuity/function
No shorts detected
Harnesses labeled at both ends

Phase 7: Rear POWERCELL Installation¶

Goal: Mount rear POWERCELL, route power and CAN

Duration: 1 session

Tasks¶

CAN Daisy-Chain¶

MASTERCELL ──► Front POWERCELL ──► Rear POWERCELL
                                        │
                                        └──► (inMOTION branches later)

Tools Needed¶

Same as Phase 4

Exit Criteria¶

Rear POWERCELL mounted and powered
CAN communication verified (3 devices)
Ready for output wiring

Phase 8: Output Wiring (POWERCELLs to Loads)¶

Goal: Connect all lighting and accessory outputs

Duration: 3-4 sessions

Session 8A: Front Lighting¶

Session 8B: Rear Lighting¶

Session 8C: Accessories & Interior¶

Wire fuel pump (with prime logic)
Wire dome light(s)
Wire wiper motor
Wire washer pump
Wire HVAC blower (if through Infinitybox)
Wire radiator fan(s) (if through Infinitybox, may need relay)
Test each circuit

Session 8D: Auxiliary Outputs¶

Wire aux light outputs (with relays if >20A)
Wire air compressor (with relay)
Wire 12V/USB outlets
Test each circuit

Reference¶

POWERCELL_OUTPUT_MAP.md — output assignments

High-Current Relay Wiring¶

For loads >20A (light bar, compressor):

POWERCELL Output ──► Relay Coil (-)
                     Relay Coil (+) ◄── Key-on or +12V

Fused Battery + ──► Relay Common
                    Relay NO ──► Load (+)
                    Load (-) ──► Ground

Tools Needed¶

Crimpers
Heat gun
Test light or multimeter
Helper (for testing lights outside truck)

Exit Criteria¶

All outputs wired per POWERCELL_OUTPUT_MAP
Each circuit tested and functional
Turn signals flash correctly (inVERT working)
Brake lights work with pedal
Fuel pump primes on key-on

Phase 9: Door Wiring (inMOTION)¶

Goal: Install inMOTION cells in all doors, wire windows and locks

Duration: 2 sessions (can defer if windows/locks not priority)

Pre-Work¶

Remove door panels (all 4 doors)
Document existing window/lock motor wiring
Verify inMOTION address jumpers set

Session 9A: Driver & Passenger Front Doors¶

For each front door:

Mount inMOTION cell inside door
Run CAN + power through door boot
Connect window motor
Connect lock actuator
Connect puddle light (if equipped)
Driver door: Connect master window switches

Session 9B: Rear Doors¶

For each rear door:

Mount inMOTION cell inside door
Run CAN + power through door boot
Connect window motor
Connect lock actuator
Connect child lock input (if equipped)

Door Boot Wiring¶

Each door needs through door boot:

Wire	Gauge
CAN-H	18 AWG
CAN-L	18 AWG
+12V constant	12 AWG
Ground	12 AWG
Door ajar (optional)	18 AWG

Testing¶

Each window operates up/down
Each lock operates lock/unlock
Master switch controls all windows (driver door)
Child lock disables rear window switches

Tools Needed¶

Trim panel tools
Crimpers
Wire through door boot (may need fish tape)

Exit Criteria¶

All inMOTION cells installed
Windows and locks functional
CAN communication shows all 7 devices
Door panels reinstalled

Phase 10: Gauge Cluster¶

Goal: Install Dakota Digital VHX, connect signals

Duration: 1-2 sessions

Tasks¶

GPS Speed Sender¶

Mount GPS antenna (dash top or under dash)
Connect to Dakota Digital speed input
Calibrate if needed

Reference¶

Dakota Digital VHX installation manual
STU Control Pack pinout (for tach, temp, oil signals)

Exit Criteria¶

Cluster installed and powered
All gauges display correctly
Indicators function with inputs
Speedometer accurate (road test)

Phase 11: STU Integration¶

Goal: Connect STU Control Pack and TC Controller to vehicle systems

Duration: 1-2 sessions

Session 11A: STU Control Pack¶

Mount STU Control Pack (firewall or inner fender)
Connect power (8 AWG fused)
Connect ground
Connect key-on signal from MASTERCELL
Connect throttle pedal
Connect engine harness (per STU instructions)
Connect transmission harness
Verify CAN termination (STU is isolated network)

Session 11B: STU TC Controller¶

Mount TC Controller (under dash or tunnel)
Connect power (fused)
Connect ground
Connect shift motor harness (to transfer case)
Connect position sensor
Connect shift switch input
Connect position indicator output to dash

Signal Integration¶

Signal	From	To
Key-on	MASTERCELL	STU Control Pack
Tach	STU	Cluster
Reverse	STU	MASTERCELL input
Check engine	STU	Cluster
TC position	TC Controller	Dash indicator

Testing¶

Engine cranks (starter relay triggered)
Engine runs (STU controlling engine)
Transmission shifts (STU controlling trans)
TC shifts 2H → 4H → 4L
Reverse lights activate in reverse

Exit Criteria¶

Powertrain fully functional
TC shifts correctly
All signals integrated with Infinitybox

Phase 12: Final Testing & Commissioning¶

Goal: Full system test, cleanup, documentation

Duration: 1-2 sessions

System Test Checklist¶

Lighting - [ ] Headlights low beam - [ ] Headlights high beam - [ ] Flash-to-pass - [ ] Parking lights (front + rear) - [ ] Turn signals (all 4 corners + indicators) - [ ] Hazard lights - [ ] Brake lights (+ 3rd brake) - [ ] Reverse lights - [ ] License plate light - [ ] Dome light (door trigger + manual) - [ ] Cargo light

Accessories - [ ] Horn - [ ] Wipers (all speeds) - [ ] Washer - [ ] HVAC blower (all speeds) - [ ] Defrost

Windows & Locks - [ ] All windows up/down - [ ] All locks lock/unlock - [ ] Master switch function - [ ] Child lock function - [ ] Key fob (if equipped)

Gauges - [ ] Tach reads correctly - [ ] Speedometer accurate - [ ] Temp gauge reads - [ ] Oil gauge reads - [ ] Fuel gauge reads - [ ] Voltmeter reads

Auxiliary - [ ] Light bar - [ ] Pod lights - [ ] Rock lights - [ ] Rear work light - [ ] Air compressor - [ ] Diff locks (if equipped) - [ ] 12V outlets - [ ] Radios

Powertrain - [ ] Engine starts - [ ] Engine runs smoothly - [ ] Transmission shifts all gears - [ ] TC shifts 2H/4H/4L - [ ] No warning lights

Road Test¶

Verify speedometer accuracy
Test all lights at night
Verify turn signal cancel
Test brake lights while moving
Verify no electrical gremlins under vibration

Cleanup¶

Secure all wire bundles
Remove temporary zip ties, replace with permanent
Install all trim panels
Clean up routing, hide wires
Apply dielectric grease to all connectors
Verify no chafing points

Documentation¶

Label both ends of every wire
Take photos of final installation
Update all planning docs with as-built notes
Record inCODE configuration backup
Create laminated quick-reference card for fuse locations

Exit Criteria¶

Phase Summary¶

Phase	Description	Depends On	Est. Sessions
1	Demolition & Prep	—	1-2
2	Power Distribution	1	1
3	Firewall Penetration	1	1
4	Front POWERCELL	2, 3	1
5	MASTERCELL	3, 4	1
6	Input Wiring	5	2-3
7	Rear POWERCELL	4	1
8	Output Wiring	4, 7	3-4
9	Door Wiring	7	2
10	Gauge Cluster	5, 11	1-2
11	STU Integration	2, 5	1-2
12	Testing & Commissioning	All	1-2
TOTAL			16-22 sessions

Parallel Work Opportunities¶

Some phases can overlap:

Phase 6 + 7: Input wiring while rear POWERCELL routes
Phase 8A + 8B: Front and rear lighting with two people
Phase 9: Can be deferred entirely if windows/locks low priority
Phase 10 + 11: Cluster and STU can be done simultaneously

Tools Summary¶

Must Have¶

Multimeter (auto-ranging)
Wire strippers (10-22 AWG)
Crimpers (ratcheting, open-barrel)
Deutsch crimper
Heat gun
Cable cutters
Drill + bits
Socket set

Nice to Have¶

inCODE programmer
Oscilloscope (CAN debugging)
Label maker (Brother P-touch)
Hydraulic cable crimper
Wire fish tape
Inspection camera