Electrical Issue on 2000 PSD
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Trailering
Joined: Aug 2020
Posts: 17
Likes: 0
12.38 V and 12.42 V. All the battery grounds are tight on batteries and block though the connectors at the neg battery cables are after market clamps (but no visible corrosion). I do have the negative cables on the 2002 I will go ahead switch over just in case. As I recall, pos cables have a different configuration and current ones on 2000 have OEM clamp connectors so I will leave them alone. I have not checked the voltage coming into the fuse panels. How do I access the input feed wires?
Logistics Pro
Joined: Oct 2011
Posts: 3,953
Likes: 120
From: Mcdonough, GA
Batteries are a little low but that's probably from all the testing. Charge them up.
Not sure on the best or easiest way to access fuse panel inputs without taking the panels loose
I also believe our 2000 model trucks have a fusible link in the power wiring. Again working from my phone im not much help. Maybe @Sous can look up a couple of wire prints for us if he gets time.
Not sure on the best or easiest way to access fuse panel inputs without taking the panels loose
I also believe our 2000 model trucks have a fusible link in the power wiring. Again working from my phone im not much help. Maybe @Sous can look up a couple of wire prints for us if he gets time.
FTE Leadership Emeritus
Joined: May 2014
Posts: 27,355
Likes: 5,950
From: Lake Hartwell, GA
There are differences in the harness between a 2002MY and a 2000MY truck, but the main battery cables may be the same, I am not sure of that. There are some fused links as well, but they are for the starting system and GP system if I am remember correctly. I would have to review the diagrams again to be sure.
The newer models have a positive terminal on the driver wheel well under the air box, but you said you used the 2000MY body, so I would not suspect that.
There are several grounds in the engine bay, specifically one for the fuse box under the hood right near the fuse box. You can remove the cover toward the front of the under hood fuse box and check for power at the lug. You can do the same for the under dash fuse box, but it is a bit more difficult to get to. If you don't have power at the lugs, the fuses themselves will not receive power.
I can absolutely help with the diagrams, but we need to try and narrow down your search a bit so that I am not attempting to upload several diagrams. I can look for something related to the fuse boxes and power distribution though in the mean time.
If you have a PC, you may be interested in using the Ford Service Manual yourself. If so, post here: https://www.ford-trucks.com/forums/1...ce-manual.html
Keep talking to us and keep us updated, you will get it eventually.
The newer models have a positive terminal on the driver wheel well under the air box, but you said you used the 2000MY body, so I would not suspect that.
There are several grounds in the engine bay, specifically one for the fuse box under the hood right near the fuse box. You can remove the cover toward the front of the under hood fuse box and check for power at the lug. You can do the same for the under dash fuse box, but it is a bit more difficult to get to. If you don't have power at the lugs, the fuses themselves will not receive power.
I can absolutely help with the diagrams, but we need to try and narrow down your search a bit so that I am not attempting to upload several diagrams. I can look for something related to the fuse boxes and power distribution though in the mean time.
If you have a PC, you may be interested in using the Ford Service Manual yourself. If so, post here: https://www.ford-trucks.com/forums/1...ce-manual.html
Keep talking to us and keep us updated, you will get it eventually.
Logistics Pro
Joined: Oct 2011
Posts: 3,953
Likes: 120
From: Mcdonough, GA
There are differences in the harness between a 2002MY and a 2000MY truck, but the main battery cables may be the same, I am not sure of that. There are some fused links as well, but they are for the starting system and GP system if I am remember correctly. I would have to review the diagrams again to be sure.
The newer models have a positive terminal on the driver wheel well under the air box, but you said you used the 2000MY body, so I would not suspect that.
There are several grounds in the engine bay, specifically one for the fuse box under the hood right near the fuse box. You can remove the cover toward the front of the under hood fuse box and check for power at the lug. You can do the same for the under dash fuse box, but it is a bit more difficult to get to. If you don't have power at the lugs, the fuses themselves will not receive power.
I can absolutely help with the diagrams, but we need to try and narrow down your search a bit so that I am not attempting to upload several diagrams. I can look for something related to the fuse boxes and power distribution though in the mean time.
If you have a PC, you may be interested in using the Ford Service Manual yourself. If so, post here: https://www.ford-trucks.com/forums/1...ce-manual.html
Keep talking to us and keep us updated, you will get it eventually.
The newer models have a positive terminal on the driver wheel well under the air box, but you said you used the 2000MY body, so I would not suspect that.
There are several grounds in the engine bay, specifically one for the fuse box under the hood right near the fuse box. You can remove the cover toward the front of the under hood fuse box and check for power at the lug. You can do the same for the under dash fuse box, but it is a bit more difficult to get to. If you don't have power at the lugs, the fuses themselves will not receive power.
I can absolutely help with the diagrams, but we need to try and narrow down your search a bit so that I am not attempting to upload several diagrams. I can look for something related to the fuse boxes and power distribution though in the mean time.
If you have a PC, you may be interested in using the Ford Service Manual yourself. If so, post here: https://www.ford-trucks.com/forums/1...ce-manual.html
Keep talking to us and keep us updated, you will get it eventually.
FTE Leadership Emeritus
Joined: May 2014
Posts: 27,355
Likes: 5,950
From: Lake Hartwell, GA
I agree, he/we are missing something that is simple. I will keep after this thread in hopes for a resolution or the opportunity to provide advice or documentation.
Thank you for tagging me as I had missed this one before hand and am interested in what the fix action will be.
Tuned
Joined: May 2016
Posts: 432
Likes: 48
From: Colorado Front Range
Don't know if this will help... but 2000 harness utilizes GEM, 2002 replaces GEM with VSM (Vehicle Security Module). Not sure if 2002 engine/body electronics can function correctly through 2000 GEM. 
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Papa Smurf
Joined: Nov 2009
Posts: 1,080
Likes: 204
From: Woodstock, GA
Had a similar thing with a Chrysler van 30 years ago. Would just go dead while driving, etc...etc... After numerous visits to shops, a friend walked up one day.... says, I bet I know what your problem is. He pulled on the negative battery cable, and sparks went everywhere.... turned out after a year of searching.... the main ground to block was loose. Costs me a lot of $$$$$ to find that fix. 
Rule out the small stupid stuff, before you declare the most expensive parts are to blame.
Rule out the small stupid stuff, before you declare the most expensive parts are to blame.
FTE Chapter Leader
Joined: Jan 2005
Posts: 13,129
Likes: 4,730
From: Henderson, NV
Had a similar thing with a Chrysler van 30 years ago. Would just go dead while driving, etc...etc... After numerous visits to shops, a friend walked up one day.... says, I bet I know what your problem is. He pulled on the negative battery cable, and sparks went everywhere.... turned out after a year of searching.... the main ground to block was loose. Costs me a lot of $$$$$ to find that fix.
Rule out the small stupid stuff, before you declare the most expensive parts are to blame.
Rule out the small stupid stuff, before you declare the most expensive parts are to blame.
It's a Van Gogh
Joined: Feb 2010
Posts: 7,813
Likes: 1,335
From: Elk Grove, CA
If a bad ground is suspected an easy way to test is to add another ground path. I have a few lengths of 4 gauge battery cables for this. Add a solid new ground and if that is no help, the OEM ground is good.
Thread Starter
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Trailering
Joined: Aug 2020
Posts: 17
Likes: 0
OK everyone, time to give you an update. Sunday I had to disassemble, move, and re-assemble a large wooden playset for the grandkids so I lost the whole day and Monday got consumed with work. I took yesterday off and focused on the truck. Going back to the simplest and most basic thing suggested, I started with the grounds. As I mentioned before, the battery cables on this truck have aftermarket clamps and while they don't appear corroded, I decided to go after the Easy button. The connections were all good and tight, however, I went ahead and pulled the negative battery cables off of the 2002 (same design) and put them in the 2000. I also aggressively cleaned all contact points on the block, frame, and body. Wouldn't you know it, everything powered up and the truck started and ran fine.
It was answered prayer and a big shout out to the FTE community. A huge thanks to all of you who offered advice and insights. Though I thought I might end up there, I was glad I did not have to go the GEM route. You saved the day and got her rolling again.
It was answered prayer and a big shout out to the FTE community. A huge thanks to all of you who offered advice and insights. Though I thought I might end up there, I was glad I did not have to go the GEM route. You saved the day and got her rolling again.
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