Ok here is a rough draft of the PCM swap. Iíll post this for any suggestions, corrections, or added info, then edit and repost. Please feel free to give me any suggestions, I'm no pro at this, just figured I had some time to write this up, and I'm just trying to help out anyone interested in this swap. I know first hand how difficult it is trying to read through 70 pages of info trying to pick up everything you need to know.
I have scans of all the pinouts and diagrams on my computer. I will upload them to this post, but I've noticed the pictures on here don't always show up the greatest. I found all of them in the 03 and 05 service manuals. Here is a website to download the 05 Service Manual. I Found the 03 stickied somewhere else. If you can't find them anywhere else, PM me and I will email you all my scans. These are available free, I had one guy on a facebook truck page offer to email them to me for $50, what a douche
OEM SERVICE MANUALS
You will need to add in a new bank of oxygen sensors, Upstream and Downstream. Add wiring from the new sensors all the way to the computer location and pin it to the connectors. You will add 6 new pins, and two wires will splice onto existing wires for a return signal.
Remove the old TCM computer from the truck. Most of these wires will be pinned onto connector C4 on the 05 PCM.
You will need to purchase a NGC connector (C4 Green) with pins. I believe you can order these online, or just go to a salvage yard and cut off a connector or two to use. The pins will come out fairly easily. Pry open the 4 tabs on the connector to remove the back, then use a flat screwdriver to unlock a red holding tab on the side of the connector. Then the pins should pull out with a good tug. The pins can be reinserted, then the red tab closed to lock the pins in solid. It may be beneficial to purchase a few extra connectors, the cover on the back of the plug has a tendency to break very easily.
Downstream sensors can be tuned out with a custom tune to remove any codes if you are not installing catalytic converters. It's recommended to add the wiring and sensors, but is not absolutely necessary in order to work.
05 sensor designatons
Sensor 1/1 Driver side upstream
Senor 1/2 Driver side downstream
Sensor 2/1 Passenger side upstream
Senor 2/2 Passenger side downstream
For adding in the new O2 sensors, the 03 truck should have the 1/1 and 1/2 sensors located on the passenger side. On the new 05 setup, Bank 1 will be the driver side; Bank 2 will be the passenger side. On my personal truck, having these reversed caused major issues with the truck running right. I had to switch pins, so my new sensors went to Bank 1 pins, and I had to relocate the existing sensors to the open spots for Bank 2.
Word of caution, it is not recommended to cut the harness off of the new sensor. The sensor wires are typically silver or aluminum, and shouldnít be soldered to copper. I used Casper Electronics O2 sensor extenders for the connectors; I cut them off and soldered them to the new wire going to the computer.
Switch Pin 31 to 33
Add new Downstream o2 signal wire to pin 31
Splice on new Upstream o2 Return to Pin 32
Add TCM Pin 46 to Pin 26 SCI Receive (TCM)
Add TCM Pin 7 to C1 37 SCI Transmit (TCM)
Add TCM Pin 38 to C1 27 5 Volt Supply
Switch Pin 18 to 17
Add new upstream o2 Heater Control to Pin 18
Switch Pin 31 to 33
Add new upstream o2 Signal
Splice on new Downstream o2 Return to Pin 32
Switch Pin 9 to 10
Add new o2 downstream heater control to Pin 9
TCM Pin 60 (OD solenoid Control) to Pin 1
TCM Pin 59 (4C Solenoid Control) to Pin 2
TCM Pin 40 (MS Solenoid Control) to Pin 4
TCM Pin 19 (2C Solenoid Control) to pin 6
TCM Pin 55 (UD Solenoid Control) to pin 8
TCM Pin 20 (L/R Solenoid Control) to pin 10
TCM Pin 18 (Pressure Control Solenoid Control) to Pin 11
TCM Pin 37 (Ground) to Pin 12
TCM Pin 53 (Ground) to Pin 13
TCM Pin 57 (Ground) to Pin 14
TCM Pin 1 (TRS T1 Sense) to Pin 15
TCM Pin 3 (TRS T3 Sense) to Pin 16
TCM Pin 49 (Tow/Haul Overdrive Off Switch Sense) to Pin 17
TCM Pin 15 (Transmission Control Relay Control) to Pin 18
TCM Pin 16 (Transmission Control Relay Output) to Pin 19
TCM Pin 48 (4C Pressure Switch Sense) to Pin 20
TCM Pin 29 (UD Pressure Switch Sense) to Pin 21
TCM Pin 9 (OD Pressure Switch Sense) to Pin 22
TCM Pin 2 (TRS T2 Sense) to Pin 26
TCM Pin 17 (Transmission Control Relay Output) to Pin 28
TCM Pin 50 (L/R Pressure Switch Sense to Pin 29
TCM Pin 47 (2C Pressure Switch Sense) to Pin 30
TCM Pin 30 (Line Pressure Sensor Signal) to Pin 31
TCM Pin 14 (Output Speed Sensor Signal) to Pin 32
TCM Pin 52 (Input Speed Sensor Signal) to Pin 33
TCM Pin 13 (Speed Sensor Ground) to Pin 34
TCM Pin 54 (Transmission Temperature Sensor Signal) to Pin 35
TCM Pin 42 (TRS T42 Sensor) to Pin 37
TCM Pin 36 (Transmission Control Relay Output) to Pin 38