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Swapping Glow plug relay

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Old Jan 5, 2021 | 12:02 PM
  #16  
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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.
 
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Old Jan 5, 2021 | 12:16 PM
  #17  
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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
 
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Old Jan 5, 2021 | 01:23 PM
  #18  
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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.
 
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Old Jan 5, 2021 | 01:54 PM
  #19  
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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.
 
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Old Jan 5, 2021 | 02:01 PM
  #20  
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From: Lockport
Yeah that's a really good idea! I'll try that before I install the new GPs!!
 
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Old Jan 5, 2021 | 02:15 PM
  #21  
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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.
 
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Old Jan 5, 2021 | 02:20 PM
  #22  
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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.
 
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Old Jan 5, 2021 | 02:26 PM
  #23  
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BTW my guide is in post #3 https://www.ford-trucks.com/forums/1...-the-cold.html
 
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Old Jan 5, 2021 | 06:16 PM
  #24  
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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.
 
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Old Jan 5, 2021 | 07:21 PM
  #25  
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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.
 
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Old Jan 5, 2021 | 07:38 PM
  #26  
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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
 
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Old Jan 5, 2021 | 09:47 PM
  #27  
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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!!!!
 
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Old Jan 5, 2021 | 10:09 PM
  #28  
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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.
 
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Old Jan 5, 2021 | 10:10 PM
  #29  
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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!!
 
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Old Jan 5, 2021 | 10:26 PM
  #30  
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watch your Voltmeter it will let ya know quick IF the GP Relay sticks.

a knife switch is not a bad idea.
 
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