I am a first time diesel owner and need some help. I have a 1996 F250 with the Powerstroke. It is around 50 degrees now here in Texas. The problem is my truck will not start unless I turn the key to activate the glow plugs several times. This sometimes will or will not work. I was told to check the glow plug controller. I checked with a test light and have constant voltage on the back post of the controller and when I turn the ignition on I have no power on the other terminal. I was told that this test would isolate the problem. So, I returned some glow plugs and have been trying to locate this CONTROLLER. I went everywhere and no luck. I was told this is a "dealer item" Any suggestions??? Am I going about this the wrong way? PLEASE HELP....its gonna get alot colder here and I wont be able to start the truck.

 

The 'controler' as you called it is actually called a 'glo plug relay'. It can be found at NAPA stores for around $20. The part # is GPR109.

That should solv your probelms. I live in the Texas Hill Country and have been starting my truck in the early morning at around 40-45 degrees with no problems.

If you still have problems as it get's colder, use your block heater. Look at the housing where you screw the oil filter onto. You'll see a large red wire coming off the front of it going twards the front, just follow that wire at it will take you to the plug. If it's never been used before it will be coild up and mounted to the frame. Take it off and rout it throught the grill or bumper. Then get you an electrical timer (wallmart sells them as do most hardware stores) and set it for about2 hrs before you leave in the morning. That way it will only send electricity to your block heater 2 hrs before you leave saving you some on your electricity bill vs. leaving it pluged in all night and it will warm the block up enough to make a huge differance when starting in the morning.
It will also help get the heater/defroster working faster.

Sorry for rambling, hopefully you'll find something in there usefull.

 

I went to the local Napa and purchased the part. The problem is the "new one has 4 connectors on top and none on the side. My old one has 2 teriminals on top and a "plug in" on the side which accepts a plug from my wiring harness. Any suggestions????

 

SORRY!!!! I got it to work. Thank you for the information. I am glad to see that there are people and web sites that do help.

Bo Brown
I too love diesel fumes!!!

 

Glad to hear ya got it! I carry a pretty large "arsonal" of spare parts (mainly cause I drive 250-300 miles per day) and a spare GPR is in there. I was out of town one time working when mine went out on me. Of cours it was during the coldes week of that year and pluging in wasnt an option. Luckly I had a spare. Been carrying another one since.

 

its also good to go around and clean all of your termainal. from the battries to the silnoid, to the glowplug relay, too the glow plugs, a little volt drop can make a differants.i had the same problem but that cured it took about a hour and cost zero!!! i do mine every 6 months or year when im sitting around doing nothing. like drinking a cool one. well just a thought!!! my 2 cents