Ok, here it is. I am new to the Forum. I have recently acquired a 86 6.9L F250 4x4 Custom Paint and a new Oak wood Bed. Awsome truck, real head turner. Here is one of my problems. No pattern to its symptoms, but sometimes when I turn the key on the wait to start light doesn't come on. After some time it will come around and start. Now I would assume that the relay/solenoid is good, because they either work or don't, no in between. I am told that there is a switch/controller that is the probable cause to my issue. That damn switch is $120 bucks at all 3 local parts stores. Really, there is nothing original to the truck anyway, so I am not after keeping it so. Can I put a switch on the dash to light the glow plugs? Any help would be appreciated.

Side Question not related - the return lines on each injector, are those just regular fuel lines that can be bought at your local parts store off of the roll? Or are they special lines that I have to try and find at a Ford Dealer? I have one leaking and would just rather change them all.

Thank you all

 

Sounds like a ground somewhere.

My '87 6.9 Motorhome does that to, but only when the engine is hot, it doesn't come on at all. Doesn't bother me, I actually preffer it that way since it only happens when it's hot enough to start without glow plugs anyways.

Now my 87 is not the same system as yours. I have the better solid state glow plug system.



For older systems, it is recommended to convert to manual glow plugs.


Heres how.

Just get a momentary push button, run a wire to the GP solenoids purple wire terminal, make sure to remove purple wire from solenoid so the truck can't control them, and then find a ignition on hot wire in the cab, connect that to the one side of the momentary switch and the wire you ran to the purple wire to the other side, bam, done.


Heres a pic to help, and any other questions you have about the truck for the engine/trans. you ask the experts over in the Pre-PowerStroke Diesel forum (Pre-Power Stroke Diesel (7.3L IDI & 6.9L) - Ford Truck Enthusiasts Forums)

Your questions won't go un-answered there.





As for the return lines, they are normal rubber lines, can't recall the size right now, and if your doing that, you'll wanna do the plastic T's and O-rings as well. International or Ford sells the kit.


Hope this helps!

 

Yes, be aware Ford used two different glowplug control systems. The earlier trucks had what was described and what is in the picture above, the later system is a little different. You should have the older system, but sometime later (87?) they went to the newer system, and there is a chance someone has swapped to the later system on your truck. That's why I am bringing it up. Don't worry, the later system can be converted to manual switch also. It's the best thing I ever did to my diesel.

You can buy the rubber lines at the store, but they must say "fuel" on them. Only Napa had the correct lines in my town, I think they were 3/16" fuel lines, I got 5 ft. I then went to tractor supply and bought a couple of packs of #111 o-rings from the hydraulic fitting section of the store(Napa might carry them also). That's the o-rings you need. I just re-used my old plastic caps since they where in good shape.

The hardest part of the o-ring job is carefully bending the fuel lines, and then getting them bent back into the right place without cross-threading the nut on the injector.