Notices
Pre-Power Stroke Diesel (7.3L IDI & 6.9L) Diesel Topics Only

Swapping Glow plug relay

Thread Tools
 
Search this Thread
 
Old Jan 5, 2021 | 12:02 PM
  #16  
lonewolf_'s Avatar
lonewolf_
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
Generally when the Controller fails the Driver transistor that closes the relay burns open and will no longer pull the relay in>

the Relays get the contacts burned over time and will stick closed even when commanded to open. the #1 cause for this is Low Battery voltage.

as far as the broken pieces you might put blankets over the heads and crank the engine over and see if those pieces get blown out.




if the pieces have already made it out of the pre-cup they may have already made it out the exhaust by now.
 
Reply
Old Jan 5, 2021 | 12:16 PM
  #17  
4drocket's Avatar
4drocket
Tuned
5 Year Member
Liked
Loved
Joined: Apr 2019
Posts: 290
Likes: 27
From: california's farmland
i read on here a guy used a shop vac hooked up to some hose and he was able to get them out that way too
 
Reply
Old Jan 5, 2021 | 01:23 PM
  #18  
lonewolf_'s Avatar
lonewolf_
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
you get a bit more access by removing the injector .... it's no easy task if the piece is side ways ... best hope is it is still stuck in the GP hole as the plug was pulled out.

anyway not a fun job.
 
Reply
Old Jan 5, 2021 | 01:54 PM
  #19  
DarkOverCast's Avatar
DarkOverCast
Posting Guru
Joined: May 2015
Posts: 2,036
Likes: 5
Originally Posted by lonewolf_
you get a bit more access by removing the injector .... it's no easy task if the piece is side ways ... best hope is it is still stuck in the GP hole as the plug was pulled out.

anyway not a fun job.
Yeah I would pull that injector and use a shop vac on one of the holes and let the other flow air to hopefully pull the pieces out IF they're even still in there or free.

You can build a little catch can out of an old jar, drill two holes in the lid and stuff a 3/8" hose in each, works good to catch metal or fluids to see what all comes out.
 
Reply
Old Jan 5, 2021 | 02:01 PM
  #20  
Dflynn926's Avatar
Dflynn926
Thread Starter
|
Senior User
Joined: Dec 2013
Posts: 115
Likes: 0
From: Lockport
Yeah that's a really good idea! I'll try that before I install the new GPs!!
 
Reply
Old Jan 5, 2021 | 02:15 PM
  #21  
lonewolf_'s Avatar
lonewolf_
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
the only other question I can think of is what is the voltage on those Bosch Plugs ... I tried but I cannot read the numbers?


Also IF you are planning on using the Ford controller then it is best to use motorcraft plugs because the controller is designed to use the PTC value of the Glow plugs in it's operation..... IF you are just gonna do a manual control of the GP relay then 12 volt plugs the next set I plan on using will be 24 Volt.
 
Reply
Old Jan 5, 2021 | 02:20 PM
  #22  
Dflynn926's Avatar
Dflynn926
Thread Starter
|
Senior User
Joined: Dec 2013
Posts: 115
Likes: 0
From: Lockport
Originally Posted by lonewolf_
the only other question I can think of is what is the voltage on those Bosch Plugs ... I tried but I cannot read the numbers?
I'll have to try when I get home from work.
 
Reply
Old Jan 5, 2021 | 02:26 PM
  #23  
lonewolf_'s Avatar
lonewolf_
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
BTW my guide is in post #3 https://www.ford-trucks.com/forums/1...-the-cold.html
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

Top 10 Ford Truck Tragedies

 Joe Kucinski
story-1

AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

 Brett Foote
story-2

Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

 Michael S. Palmer
story-3

Ford's 2001 Explorer Sportsman Concept Looks For a New Home

 Verdad Gallardo
story-4

10 Best Ford Truck Engines We Miss the Most!

 Joe Kucinski
story-5

2026 Shelby F-150 Off-Road: Better Than a Raptor R?

 Brett Foote
story-6

2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

 Michael S. Palmer
story-7

10 Most Surprising 2026 Ford Truck Features!

 Joe Kucinski
story-8

Top 10 Ford Trucks Coming to Mecum Indy 2026

 Brett Foote
story-9

5 Best / 5 Worst Ford Truck Wheels of All Time

 Joe Kucinski
Old Jan 5, 2021 | 06:16 PM
  #24  
DarkOverCast's Avatar
DarkOverCast
Posting Guru
Joined: May 2015
Posts: 2,036
Likes: 5
Originally Posted by lonewolf_
the only other question I can think of is what is the voltage on those Bosch Plugs ... I tried but I cannot read the numbers?


Also IF you are planning on using the Ford controller then it is best to use motorcraft plugs because the controller is designed to use the PTC value of the Glow plugs in it's operation..... IF you are just gonna do a manual control of the GP relay then 12 volt plugs the next set I plan on using will be 24 Volt.
I think the Humvees used 24v glow plugs, now I'm not positive on the thread, but the 6.5 looks the same size, and those plugs use a regular spade connector, not the extra wide kind like the ZD-1's.

Maybe there not even the right thread or length, but they're a 24v option that is readily available. I think it would be hard to burn them out, although they may have to cycle for longer to make the same heat.
 
Reply
Old Jan 5, 2021 | 07:21 PM
  #25  
lonewolf_'s Avatar
lonewolf_
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
10mm x 1.0 pitch same as the old 6.2 hummer engines they come in Bullet style too.
The seat is the same angle but Thread depth is a bit different, they will fit fine I did that on my old 83 years ago too.

and yes they will take longer to heat but due to my area I never need to hit the 12v plugs longer than 3 secs... so 3 or 4 secs down here is plenty long enough on the 24V plugs.
 
Reply
Old Jan 5, 2021 | 07:38 PM
  #26  
DarkOverCast's Avatar
DarkOverCast
Posting Guru
Joined: May 2015
Posts: 2,036
Likes: 5
Originally Posted by lonewolf_
10mm x 1.0 pitch same as the old 6.2 hummer engines they come in Bullet style too.
The seat is the same angle but Thread depth is a bit different, they will fit fine I did that on my old 83 years ago too.

and yes they will take longer to heat but due to my area I never need to hit the 12v plugs longer than 3 secs... so 3 or 4 secs down here is plenty long enough on the 24V plugs.
Good to know, I may look into a set of bullet point ones now that it's confirmed they work
 
Reply
Old Jan 5, 2021 | 09:47 PM
  #27  
Dflynn926's Avatar
Dflynn926
Thread Starter
|
Senior User
Joined: Dec 2013
Posts: 115
Likes: 0
From: Lockport
Well folks. Vacuumed the hole. No luck. I replaced the glow plugs. Tested them all first, both ohm and plugged in. All worked great (motocraft). Installed and torque. Cycled 2 times for 7 on 5 off. It's 28 and I have the fuel line item the other day. Cranked it, cycled it 3 more times, cranked, popped once, cycled it again then cranked. Ran then died. Cycled one more time, cranked and fired up. Sounds awesome!! Thank you all so much I really appreciate it!!!!
 
Reply
Old Jan 5, 2021 | 10:09 PM
  #28  
DarkOverCast's Avatar
DarkOverCast
Posting Guru
Joined: May 2015
Posts: 2,036
Likes: 5
Originally Posted by Dflynn926
Well folks. Vacuumed the hole. No luck. I replaced the glow plugs. Tested them all first, both ohm and plugged in. All worked great (motocraft). Installed and torque. Cycled 2 times for 7 on 5 off. It's 28 and I have the fuel line item the other day. Cranked it, cycled it 3 more times, cranked, popped once, cycled it again then cranked. Ran then died. Cycled one more time, cranked and fired up. Sounds awesome!! Thank you all so much I really appreciate it!!!!
That's great!

Sounds like you had some air in the system, either from an intrusive leak, or when you had the return lines loose.
 
Reply
Old Jan 5, 2021 | 10:10 PM
  #29  
Dflynn926's Avatar
Dflynn926
Thread Starter
|
Senior User
Joined: Dec 2013
Posts: 115
Likes: 0
From: Lockport
Originally Posted by DarkOverCast
That's great!

Sounds like you had some air in the system, either from an intrusive leak, or when you had the return lines loose.
I'm hoping it's from having the lines off. But man am I excited!!
 
Reply
Old Jan 5, 2021 | 10:26 PM
  #30  
lonewolf_'s Avatar
lonewolf_
Scope Wizard
Joined: May 2019
Posts: 6,530
Likes: 25
watch your Voltmeter it will let ya know quick IF the GP Relay sticks.

a knife switch is not a bad idea.
 
Reply



All times are GMT -5. The time now is 11:58 AM.

story-0
Top 10 Ford Truck Tragedies

Slideshow: Top 10 Ford truck tragedies.

By Joe Kucinski | 2026-05-18 19:34:33


VIEW MORE
story-1
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

And it might be even better than that.

By Brett Foote | 2026-05-18 19:26:42


VIEW MORE
story-2
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

Slideshow: Does lowering an F-150 Lobo RUIN the ride quality?

By Michael S. Palmer | 2026-05-18 19:20:37


VIEW MORE
story-3
Ford's 2001 Explorer Sportsman Concept Looks For a New Home

Slideshow: Ford's bizarre fishing-themed Explorer concept has resurfaced after spending decades largely forgotten.

By Verdad Gallardo | 2026-05-12 18:07:46


VIEW MORE
story-4
10 Best Ford Truck Engines We Miss the Most!

Slideshow: The 10 best Ford truck engines we miss the most.

By Joe Kucinski | 2026-05-12 13:09:47


VIEW MORE
story-5
2026 Shelby F-150 Off-Road: Better Than a Raptor R?

Slideshow: first look at the 810 hp 2026 Shelby F-150 Off-Road!

By Brett Foote | 2026-05-12 12:50:07


VIEW MORE
story-6
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

Slideshow: Everything You Need to Know about the 2027 Super Duty Carhartt Package!

By Michael S. Palmer | 2026-05-07 17:51:06


VIEW MORE
story-7
10 Most Surprising 2026 Ford Truck Features!

Slideshow: 10 most surprising Ford truck options/features in 2026.

By Joe Kucinski | 2026-05-05 11:17:22


VIEW MORE
story-8
Top 10 Ford Trucks Coming to Mecum Indy 2026

Slideshow: Here are the top 10 Fords coming to Mecum Indy 2026.

By Brett Foote | 2026-05-04 13:49:49


VIEW MORE
story-9
5 Best / 5 Worst Ford Truck Wheels of All Time

Slideshow: The 5 best and 5 worst Ford truck wheels of all time

By Joe Kucinski | 2026-04-29 16:49:01


VIEW MORE