2002 ignition switch fuse keeps blowing

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May 7, 2023 | 04:11 PM

RigCity

Thread Starter

Laughing Gas

Joined: Jan 2017

Posts: 1,223

Likes: 94

2002 ignition switch fuse keeps blowing

My truck turned off and I found the ignition switch fuse blown. I put a new one in as expected it blew again. Any ideas thanks? Truck cranks strong

May 7, 2023 | 04:23 PM

RigCity

Thread Starter

Laughing Gas

Joined: Jan 2017

Posts: 1,223

Likes: 94

There is no wait to start light my tuner says pcm not responding. Fuse 22 was in order. Recently replaced the IPR,ICP, alternator and starter. There is enough oil in the pan as well(guess who has a no start thread due to low oil lol). I was leaving a gas station and the truck just shut down. A beautiful girl came up help I’m currently on full recon at the bar since I’m broken down a few blocks from HQ lol////also flipping out I’ll be letting down 2 clients and one of my own projects if I don’t get this figured out.

May 7, 2023 | 07:29 PM

udsuth78

Lead Driver

Joined: Oct 2005

Posts: 6,129

Likes: 1,919

From: Ponca City, OK

Is your fuel bowl heater still installed and connected? If so unplug it and install a new fuse. Don't worry about the heater, it's nothing more than a liability.

May 7, 2023 | 08:04 PM

RigCity

Thread Starter

Laughing Gas

Joined: Jan 2017

Posts: 1,223

Likes: 94

After doing returning to the truck I swapped in the wiper 30 amp fuse in the ignition position and it didn’t blow. Then when my new assistant was leaning on the aih/gpr relay area checking the hpop oil level the truck made a noise, dash lights came on then fired up after an extended round of cranking. Fuel bowl heater connector was so rough it was chopped off long ago. The engine harness hasn’t appeared in the best condition since owing the truck. For now the truck is operating as usual. Will probably order a new harness sooner than later. Going to remove it when doing glow plugs this week and further inspect. Not sure if it’s the issue just on the list of items to be replaced.

May 8, 2023 | 08:35 AM

AubieTN

Tuned

Joined: Jun 2007

Posts: 431

Likes: 66

RigCity,
These trucks are amazing. However, with their age along with some high mileage with a lot of heat under the hood while driving these high miles the wiring takes a beating and eventually becomes brittle exposing cracks causing possible misfires, stalls, shutdowns while driving and no starts.
I too (2002) had issues and replaced the entire main harness some years ago under my name “lhud”. It was pricey but the truck was a work truck driven most anywhere in the country much of the year.
Hang in there.

May 9, 2023 | 02:05 PM

RigCity

Thread Starter

Laughing Gas

Joined: Jan 2017

Posts: 1,223

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Hanging in there new harness ordered!!! Plenty of the connectors are messed up so it’s not that big of a deal more of a frustration if it dosent solve this issue. New glow plugs, valve cover gaskets and uvch on site! Seems I may have a few tired GP but I’d rather replace than find out as my truck as well goes on longer trips. Replacing my IPR on the road cost a decent amount even with the dealership giving me a great deal on the part. Rather over-replace at home than solve on the road.

May 14, 2023 | 03:01 PM

RigCity

Thread Starter

Laughing Gas

Joined: Jan 2017

Posts: 1,223

Likes: 94

Located 4 of the lager wires that cross the valley frayed making contact today when doing the swap. Will check into the color code later to determine their function. It’s amazing how far the truck has carried me with this issue that definitely did not appear overnight.