Glow plug controller troubleshooting 6.9idi
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New User
Joined: Jun 2019
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From: boone NC
Glow plug controller troubleshooting 6.9idi
I have searched and searched the forum here trying to find a beginning to end way to troubleshoot the the glow plug controller. I have replaced the glow plugs and used the correct Motocraft plugs. The issue I am having with my truck is that it needs and extra boost to fire. It will fire with the most minimal amount of ether in the world and it will crank every time. I have already put a return line kit on it and it has helped tremendously (before it was much harder). I am getting 9v at the female plug going to the glow plug. It also making a clicking but it seem that the controller is working because its sending voltage to the plug. I know the controller read resistance is there a way to test how much resistance each plug is getting or not getting.
Logistics Pro
Joined: Jun 2017
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From: Edmond, OK
Measure the resistance of the GPs with a multimeter. + lead to the tip of the GP and - lead to the engine block. You should read .3 - .8 ohms.
If your GP controller cycles then you probably have dead GPs. I replaced the GP controller in the back of the driver's head on my 6.9l idi and it started cycling / hard starting after about 6 months. I just wired the GP relay to a momentary push switch and bypassed the GP controller. Now it starts easy with about 8 seconds of GPs.
If your GP controller cycles then you probably have dead GPs. I replaced the GP controller in the back of the driver's head on my 6.9l idi and it started cycling / hard starting after about 6 months. I just wired the GP relay to a momentary push switch and bypassed the GP controller. Now it starts easy with about 8 seconds of GPs.
Logistics Pro
Joined: Jun 2017
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From: Edmond, OK
The clicking sound you hear is the GP controller turning the GP relay ON/OFF. Bad GPs will cause the GP controller to do this, but since you just replaced the GPs with new Motorcrafts it indicates that your GP controller or GP relay is bad. As I mentioned, my NEW GP controller failed after 6 months so I just put a manual switch in to activate the GP relay.
Scope Wizard
Joined: May 2019
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that old style Aluminum Case GP timer was never a good idea to begin with as it acts as an Anode in the cooling system and is short lived.
I prefer Manual enabled Plugs myself but this is not without it's drawbacks, when I do a Manual setup I use 12V Glow Plugs instead of 6 volt types.
I prefer Manual enabled Plugs myself but this is not without it's drawbacks, when I do a Manual setup I use 12V Glow Plugs instead of 6 volt types.
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From: boone NC
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Scope Wizard
Joined: May 2019
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an Aftermarket TX41 runs about 50 bux ... IF you pay much more than that then you are getting Ripped Off IMHO
there are also Aftermarket "universal glow plug timers" that you could search that cost Less than the Aftermarket TX41
East Coast Diesel has a controller for like 30 bux
Finding a Motorcraft unit might be a bit harder and most folks selling them are pretty Proud of em ......
there are also Aftermarket "universal glow plug timers" that you could search that cost Less than the Aftermarket TX41
East Coast Diesel has a controller for like 30 bux
Finding a Motorcraft unit might be a bit harder and most folks selling them are pretty Proud of em ......
Logistics Pro
Joined: Jun 2017
Posts: 3,952
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From: Edmond, OK
I bought an aftermarket TX41 for about $50. I thought it was Diesel Rx but they don't make them anymore. Anyways... 
If you decide to replace the controller it requires a large wrench. I suggest soaking it in PB Blaster for a week before removal. Make sure you tighten/loosen it a bit each night so it will finally come free.
If you decide to replace the controller it requires a large wrench. I suggest soaking it in PB Blaster for a week before removal. Make sure you tighten/loosen it a bit each night so it will finally come free.
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
I bought an aftermarket TX41 for about $50. I thought it was Diesel Rx but they don't make them anymore. Anyways...
If you decide to replace the controller it requires a large wrench. I suggest soaking it in PB Blaster for a week before removal. Make sure you tighten/loosen it a bit each night so it will finally come free.
If you decide to replace the controller it requires a large wrench. I suggest soaking it in PB Blaster for a week before removal. Make sure you tighten/loosen it a bit each night so it will finally come free.
I think East Coast Diesel sells the Diesel RX product... you would need to check with them I guess as there are several options and possibly they are just sending out the new style controllers to replace the one that screws into the head, although I don't know where they would suggest to mount it.
