Hendrickson Fords

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Hendrickson Fords 1980-1996 F-Series Trucks

Been a minute, we are getting prepared for a busy couple projects coming up!
10/05/2026

Been a minute, we are getting prepared for a busy couple projects coming up!

09/19/2026

Always have some basic tools with you! And oh ya, a motorcycle helps 😂

1996 F-150 4.9L / ZF-5 After swapping my 95 truck over to the 96 style of MAF EFI last year, I have learned a lot about ...
09/12/2026

1996 F-150 4.9L / ZF-5

After swapping my 95 truck over to the 96 style of MAF EFI last year, I have learned a lot about how these trucks computers work. I am writing this so that in the future it may assist with troubleshooting issues.

The issue started a few months after the swap, driving home when the truck had a increase in RPM, then shuttered and shut off. Immediately I jumped out and changed out the ICM (always have a spare). Then I started the truck up, it ran down the road a bit and stalled again. I was able to limp it home pulling over a few times.

Over the next year I replaced many different components, each troubleshooting and spending time researching the possible issue.

Items replaced:
ICM x3
ECU x3
ECU Relay
Distributor x2
DPFE Sensor
TPS
Fuel Pumps

The issue ended up being a wiring harness melted on the EGR, but how I got there is the real reason I am writing this. How I found it, with the truck key on I was grabbing the harness in behind the motor to check for issues. When wiggling the harness I heard the fuel pump come on, signalling the ECU had powered up. From there I took the harness out, repaired it and installed it in a proper location.

When troubleshooting, it is easy to throw components at it, especially when the issues are intermittent. Often it seems like that is all you can do. I found most of this information using the Google AI, it searches all the old forums (the ancient scrolls) to find someone who has posted something similar.

5.0V:
The ECU sends out its signals through a 5.0V reference. This voltage gets sent to TPS, DPFE, and any other components that require the feedback to ECU. Testing for the 5.0V at the TPS is the easiest way to start. Any shorts or draw on the system, the voltage will drop. If an issue is present and depending on the severity, the ECU will shutdown in a safe mode if it gets too hot from overcompensating for the drop in voltage.

Fuel Pump Function
Initially I believed the issue was the fuel pump relay getting shut off and not the entire ECU. The fuel pump runs initially before start up, and constantly when running. The ECU will know the motor is running from the PIP sensor in the distributor, this acts like a crank sensor in the early trucks.

In the future I hope this helps someone who is experiencing the same issue.

Calypso loaded up to be sent back to our Aldergrove shop for a clutch replacement!
09/04/2026

Calypso loaded up to be sent back to our Aldergrove shop for a clutch replacement!

Wishing our brother-from-down-under safe travels back to Australia! Thanks for all the help with these Fords over the la...
08/31/2026

Wishing our brother-from-down-under safe travels back to Australia! Thanks for all the help with these Fords over the last 2 years. Looking forward to the return 😎

Rig's asking us to stop our summer plans and get back to working on trucks!
08/25/2026

Rig's asking us to stop our summer plans and get back to working on trucks!

Crack truck not looking so crack looking anymore 😎
08/20/2026

Crack truck not looking so crack looking anymore 😎

A fresh look on the front 😁
07/14/2026

A fresh look on the front 😁

For Sale! Selling my personal F-250 later this month, HF followers get first dibs! 1994 F-250 5.8L 4x4Bunch of recent fi...
07/07/2026

For Sale!

Selling my personal F-250 later this month, HF followers get first dibs!

1994 F-250 5.8L 4x4

Bunch of recent fixes and upgrades. Time to get the F-150 back on the road.

10k obo!

06/30/2026

First start of "Calypso", always good to know these trucks run before assembling the rest!

Next up is to get a belt system and coolant to perform a longer test!

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Langley, BC

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