Greetings,

I highly recommend remote-mounting a new FSD onto a unit called an FSD
Cooler (search on the net and eBay and you should find several flavors of
them).  My preference is to purchase a new FSD and FSD cooler and install as
directed.  Don't bother trying to remove the original FSD from the fuel
injection pump because it is a very involved process that requires the
removal of the intake manifold just to gain access to it, and frankly it's
not worth the time and effort since you probably already have a bad FSD so
why bother.

You can read about the FSD Cooler here:
http://www.thedieselpage.com/reviews/FSDCooler.htm  I've seen them for sale
for $125-150.

If you purchase an FSD Cooler you will not need anything special to mount it
to your motor other than a very few basic tools.  The stock wiring harness
will reach if you fish the end up from the old FSD to the new one on the
cooler.  You can purchase a harness extension, but you only really need that
if you want to mount the cooler and new FSD on your firewall or fender well
(nice, but not necessary).

If you catch a failing FSD quickly enough you can avoid damage to your fuel
injection pump.  Excess heat from the FSD not only kills the FSD itself, but
fries the optical sensor inside the pump (requiring a completely new pump to
the tune of around $1800).  Plus the heat also thins out the fuel inside the
pump which decreases its lubricity and speeds up internal wear.

The new FSD needs to be indexed by using a numbered resistor to regulate the
amount of fuel.  The numbers range from 1-9 for trucks (up to either 15 or
20 for marine diesels - the higher the number, the more fuel), and a new
unit will come with a #5 resistor.  Unless you are really souping-up your
motor for extra power by adding all sorts of performance upgrades then the
#5 will be just fine and most likely is what came with your truck from the
factory.  The resistor pack sits inside the socket for the FSD's wiring
harness inside the FSD so it's almost impossible to remove and reuse your
old one.  Stick with the #5 and you will be fine.  A new FSD also comes with
a heat transfer pad so don't bother buying a new one of those, either.

You do not need any special diagnostic tools or anything to recalibrate your
motor.  This is a plug-and-play operation.

If you suspect this is only the FSD failing, then do this quick!  If you let
it go you will be out for the cost of a new fuel injection pump as well, and
I hope you don't have to go through that.

Cheers - Jonathan