[updated:LAST EDITED ON 03-Dec-02 AT 08:21 PM (EST)] There I was, doing 70 mph down the freeway, when all of a sudden, it was like someone flipped a switch and turned off the PSD. I coasted to the shoulder, and started scratching my head. I tried to start it again, no dice. I noticed the "Wait to Start" light didn't come on. I checked all the fuses inside, and then went under the hood. 30 Amp fuse listed as #22 in my '96 owners manual was blown. I had no extras, but fortunately I wasn't towing the trailer today, so I traded for the trailer brakes fuse, also 30 Amps. Started right up. I made it to a truck stop, and bought the few big 30 Ampers they had, and headed for home. 50 miles later, it did it again. Only took me a couple minutes to get back on the road this time, but obviously, there is a more serious problem going on here. The manual says the fuse is for the glow plug controller, but there must be more to it than that. It's a '96 F-250 HD 4x4 PSD.
Can someone (Joe, ya out there?) tell me what else this fuse protects, what might be causing my problems? I just had work done on it a week ago, replacing injector o-rings, and a couple of injectors. It ran perfectly for some 1200 miles towing a travel trailer. But it rained all day yesterday, and today I seem to have a short. Could the rain be related? Am I ever going to have confidence in this diesel engine experiment? Gotta go to Phoenix tomorrow, looks like it will be in the '86 (rough old 350). Please help.

 

Once the engine is running the glow plug system can be disabled and the engine should keep running. There must be something else on that 30 amp circuit (maybe the ECM power relay or the IPR -- I don't know). You are going to have to get a wiring diagram and trace it out.

 

check around the area where the mechanic was working. he may have pinched some wires, or perhaps an electrical connection wasnt put together securely. regardless, i would take it back to where it was worked on and explain your problem to them, since more than likely its related to the work they did.
eden

 

This is an interesting problem. Have you got it figured out yet? Thanks for the update.

 

[updated:LAST EDITED ON 10-Dec-02 AT 10:16 AM (EST)]No, I haven't figured it out yet. I talked to the place where I had the work done, and of course, they want me to bring it back in and leave it. I can't do that for a few days, so in the meantime, I'm carrying a bunch of spare fuses around with me. It hasn't done it since that first day, though.

 

Here is the problem mine had:

The 30A fuse (#22 underhood) blew and my PSD would not start. Replacing the fuse did not work as it blew as soon as the key was turned (@$2.00 each). After several hours of trouble shooting circuits I found it was my fuel heater. It had shorted internal to the filter canister . I like my PSD but this is a poor/cheap design. Also, I discovered that when the fuel water drain is activated it will not drain all the fuel/water from the canister, this is why the heater corroded and failed. Then to make it worse the dealer want $55 for a replacement . International/Ford really screwed this one up.

 

You've obviously had your truck long enough for it to be out of warranty or you wouldn't be complaining about the cost of the fuel heater. What did you think -- that every component was going to last forever? Call the waaambulance!!

 

[updated:LAST EDITED ON 19-Dec-02 AT 04:32 PM (EST)]Well, CEOBS1, it sounds like my problem might be related to yours. I had planned to take it in to the "local" diesel shop (about 100 miles from here), when it blew two fuses in rapid succession trying to start it, and then drained the battery in the process. I spent the rest of the day getting it charged back up and finally started, but missed my opportunity to leave it in the shop for a few days. I'll have to try again soon, as it keeps blowing fuses at inopportune times, like today, again in the fast lane with traffic all around. I agree with you Joe, I don't expect things to last forever, but I'm getting pretty burned out on this truck.
It seems to act up the day after it rains. I wonder if water into the fuel tank/then filter somehow exacerbates the problem?? Until I can get it fixed, I'm going to try draining the filter out pretty often and see if that keeps me from being dead in the fast lane.
Yes, the fuel heater is on that circuit, and the glow plugs. I still don't see why it shuts off dead when the fuse blows. Today I noticed the RPM needle quickly dropping to zero before I noticed anything else...I think I was already decelerating with traffic. Everything quit on the dash, only the battery light came on. It's like that fuse runs EVERYTHING, though of course the wiring diagrams don't show that.

 

If CEOBS1 is correct (and he may be), try unplugging the fuel heater and see if it still blows the fuse. There are probably 3 wiring connectors attached to the fuel filter cannister, depending on what year your vehicle is. One is attached to something that looks like a sending unit, it is the vacuum switch that lets the system know when the filter needs to be changed, one at the very bottom is the water in fuel connector and the one right above that is the fuel heater. That is the one you want to unplug.

 

The heater is on back order from the local Ford Dealer, best date is 15Jan03. The International dealer told me that they don't carry the part as it is a Ford design. I am driving it without the heater and the terminal disconnected. Everything is just fine:-) .