I have a 92 truck automatic transmission bought the truck from wifes grandpa, Wife wanted it sentimental thing, needed a truck to leave at the lake to put boats in. Truck had been sitting for about 3 years water pump was leaking. Changed water pump, Starter, Batteries and I drained one of the tanks put clean fuel in, installed a temp electric fuel pump to purge fuel line cranked on truck with glow plugs out to clear fuel out changed fuel filter. Long story short, new injector pump, return line kit, Injectors, Glow plugs. The connector on the fender with the glow plug wires (yellow) was smoking so I bypassed the connector. Truck starts and runs fine but the Glow plugs are kicking my butt. The truck will only start if take the wires to the glow plugs and touch them to the yellow wire lug on the relay for about 10 seconds then it starts and dies and eventually starts after a couple of times and runs fine. Relay was bad changed relay and now it just clicks rapidly for about 20sec, everything I read said relay is bad, so I purchased the whole controller with relay still clicks rapidly. Glow plugs that came with kit were diesel Rx plugs that ohm at .7 all of them, I have power to all glow plugs, pulled them again and rechecked ohms on them. The ground to the controller is good checked it with volt meter. Sorry about the length but sometimes all information is good.
Questions
What is considered good ohms on glow plugs there is so many posts but they don't talk about .7 they only talk about .3 or .4.
After reading tons more posts about the clicking and seems that the clicking is either a bad relay but couldn't it be the controller sensing too much resistance? and if so what next...
The only thing left is to build or buy and new glow plug harness( started pulling mine out and see know problems yet) Or changing it over to a manual glow plug system, but I hate to do that with all the money I spent on the controller.
Truck is nickel and diming to death, not to mention wearing me out.

Thanks for any help on this....

 

the rapid clicking after 8-10 seconds is normal, the engine once started, keeps the glows warm, a timing circuit in the controller times out after approx. 2 min, (in case you leave the key on) if it keeps clicking after engine is started, you may have intermittent power to controller, or controller is bad, remember it is almost impossible to purchase a relay only, that is the correct one, as they will sell you a start relay, (they look the same) but start relays ground through the body of relay and glow relays do not. the controller will not function correctly with wrong relay. the wait to start lite is not a indicator of glows heating, just the controller thinking.

 

The glow plug relay starts rapidly cycling when I turn the key on. The relay came with the new controller that is on now, with a test light on the wire to the glow plugs the light rapidly goes on and off in less than a 1/2 second I will check my ground again tomorrow thanks

 

check that you have it wired correctly, look at the stickys at the top of the forum look at pictures. one of the big wires go's to glow's the other to the batt with a fusible link. the other connections one is hot with key on, and other one connects to controller, and the ground gos into controller. if you have a short or miss wired it can make controller malfunction.

 

welcome to FTE.
another thing to consider. the glow plug system on these trucks is designed for motorcraft ZD-9 glow plugs.
not wellmans (diesel rx) not champions. not autolites. not acdelco.
the ohm measurements listed are for motorcraft plugs.
and the controllers are resistance sensitive.
so while the aftermarket glow plugs may work when connected to a 12 volt source, they may or may not work when connected to the ford controller.