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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Blown Fuse

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Old Jun 24, 2011 | 02:27 PM
  #16  
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dchamberlain
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I do have wiring diagrams, if they will help. I may also be able to come up with a diagram showing a particular connector location if I know the connector number also.

I have 5 diagrams. Here are the first three.
 
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Old Jun 24, 2011 | 02:28 PM
  #17  
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And the last two.
 
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Old Jun 24, 2011 | 03:25 PM
  #18  
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Since last post have removed battery tray on drivers side to try and do what you recommended on disconnecting the harness, it goes directly into a LARGE main harness that doesn’t disconnect.
Hold on..........
Followed the rear wiring, it splits off right by the master cylinder. There is two connections(grey and brown), disconnected the brown one and tried the lights...running lights work with no blown fuse. The break lights don’t work when i did this. I need to look up the brown pig tail connection and follow it back.
Thanks for your help "dchamberlain" and will keep posting the findings.
 
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Old Jun 24, 2011 | 05:46 PM
  #19  
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Originally Posted by Texas 6.0
Pulled dash:
1) Disconnected gauge cluster and all that is connected to the main dash, light switch, radio etc. == Fuse did not blow but had no way to test running lights.
2) Reconnected the light and dimmer switch, == fuse blew about 45 seconds with the running lights on.
3) Reconnected gauge cluster with everything else disconnected == fuse did not blow but had no way to test running lights.

Does this mean the problem is in the wiring between the light switch and the lights themselves?


Check for a shorted instrument panel bulb that is turned on by the side marker / dimmer switch.

The problem of those plastic bases and the metal in them getting fatigued and failing is documented in tech folder under my posts.


Simple test --- with every single bulb illuminating panel taken out (do instrument cluster first, then do the other things like HVAC panel)

Including the signal bulbs.

Does it still blow?

If yes, leave bulbs out for now.

then take bulbs out of the HVAC panel and see if it still blows.

If it still blows, it is a wrong lead.

If it stops blowing with the panel / HVAC panel bulbs out... you isolated it to those bulbs and their plastic base and the metal clasp.

----------------------

Before replacing bulbs,

take each bulb out and inspect the base / bulb for fit / wear / short.


Replace the entire set of bulbs with brand new bases and bulbs.

-----------------------

I strongly suspect it is there.
 
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Old Jun 24, 2011 | 06:40 PM
  #20  
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Originally Posted by Texas 6.0
Since last post have removed battery tray on drivers side to try and do what you recommended on disconnecting the harness, it goes directly into a LARGE main harness that doesn’t disconnect.
Hold on..........
Followed the rear wiring, it splits off right by the master cylinder. There is two connections(grey and brown), disconnected the brown one and tried the lights...running lights work with no blown fuse. The break lights don’t work when i did this. I need to look up the brown pig tail connection and follow it back.
Thanks for your help "dchamberlain" and will keep posting the findings.
As near as I can tell that is the main harness going to the rear of the truck. That pretty much isolates the problem. Follow that harness back as best you can and look for places where it has chafed against the frame or cab metal. Somewhere back there I'm sure you'll find a spot that is rubbed through.
 
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