I've got a 1994.5 IDI Ford 7.3 Turbo that seems to be getting more difficult to start as winter approaches.

I changes all the glow plugs with ford brand plugs first off. When I was doing so I noticed some of the white plastic tips that transfer the voltage are cracked. I had the local ford shop also change the relays (I think there was 2) so they were both new.

I turn the key and the wait to start comes on, however the truck usually takes 2 or more (5) tries before it fires. I also noticed that there is a clicking sound coming from the relay for another 8ish seconds when the glow plug indicator goes off.

In the case the truck fires up, the ticking will continue for the 8ish seconds and the headlights, dash lights, etc will all pulse for the full 8 sec. If the truck doesn't start first crack, the ticking will always follow.

I tried to get the wiring harness from Ford (F3TZ-9A451-A) and it is no longer available. Neither are the plastic glow plug ends. Any links??

One mechanic I talked to told me the tickling is the trucks way to keep cycling the glow plugs to prevent white smoke on start up.

Any ideas on what is wrong ..... don't like being stranded out in the cold!!

THX!!

 

in the morning unscrew the fuel filter and see if it's full to the brim.if not,you've got an air leak allowing fuel to drain back down the lines,loosing it's prime.
of course having good connections to the gp's is a must.
the clicking/cycling of the gp's after the WTS light goes out is normal.
this provides some more heat/afterglow to help the engine stay running/run smoother at start up.

first you want to be sure the starting system is up to par.you want an engine that spins over super fast.good bats,cables,starter etc.

a little nitpicking:
you have a '94 idi truck.the '94.5 would indicate the powerstroke.
(though i don't know if there really was a "mid year" change or not,we all use '94 diesel as the idi and '94.5 for powerstroke though.)
ps.welcome to the site!
don't worry about your screen name lol.we'll forgive ya.

 

multiple clicks means the relay is turning on off on off on off... the controller does this when theres a bad plug or more OR if they arent getting connection. They might do it if they go bad too idk though. fast repetitive clicking is not how they keep warm... just a sign that the plugs arent all there (dead or bad connection)

Easy to test glow plugs just take a continuity tester on the positive batt terminal and touch the end to the tip of the glowplug stickin out the head and if she lights the glowplugs good. no light=bad plug

 

A simple one but I've talked to a few that didn't know this; are you giving half throttle in cool weather while starting? This is what the Ford manual specifies. I'm pretty sure they say full throttle when its very cold as well, but I can't remember the temperatures they stated for this.

I thought bad plugs were indicated by unusually short glow time? My controller has always cycled every few seconds after WTS comes off, even with new plugs.

 

Some great points and THANKS!! I will most definitely try the half throttle trick in colder weather and check up on the fuel filter. I have two brand new 850cca batteries and new glow plugs all around. The truck cranks over great. I did notice when I replaced the glow plugs there were a few plastic caps broken so I will asume that is where the electrical connection problem is. Does anyone know where a guy could get a gp harness or plastic end caps that fit up to the glow plugs?? .... ford has listed them as unavailable and the local parts guys can't get them either.

Also - can a new glow plug be bad??

THANKS AGAIN!!

 

The best way to fix the harness is to simply rebuild it with new ends or make a whole new one. I used the crimp on style bullet connectors from Napa and took of the shielding to solder them instead of crimping. I then squeezed the plastic cover back on and sealed with heat shrink tubing.

As for the clicking, you described a perfect working gp controller. If it starts clicking right away when you turn on the key it's a shot controller. If the WTS light is only on for a few seconds and then fast clicking it means you need to replace one or more gp's. If the WTS is on for 8 to 12 seconds depending on how cold it is, followed by rhythmic clicking that is just the gp's cycling to keep them hot.

I would for sure check the fuel filter... air intrusion can make starting as hard as not having all the gp's working. Combined they can park your rig!

Standard cold weather start for me... 30 degrees and below. Turn on key, pump pedal to the floor once then hold at 3/4 throttle, turn over as soon as the WTS goes out. Usually fires right up with a nice puff of smoke.

 

I have a 1999 7.3 diesel that i went out to strat last night and turned the key waited for the light but noticed that there was a continuing clicking sound, i turn the key back off than did the wait to start again same sound after light went off tried to start it it turned over than quit I had nothing no cranking. I did hear a clicking sound under my dash in the fuse panel it was the relay i pulled it out and the clicking stopped. I put it back in and tried to start and it was dead, and the clicking started again removed the relay and it stopped. any ideas? this truck has been nothing but trouble since i got it!!! already had to replace the stearing column because the wires rub and caused a sort.

 

Your in the wrong forum bud, need to hit up the powerstroke guys.