94 non-turbo 7.3L Diesel

In the morning when I go to start my engine occasionaly the glow plugs won't cycle. This makes it almost impossible to start the engine due to the cooler 50 degree climate I live in. The strange thing is the "wait to start" lamp will come on for about 5 seconds turn off, so I'll crank the engine but it will not start. Most of the time during and after the "wait to start" indicator turns off I can hear a clicking noise due to the glow-plugs cycling. (If I hear the "clicking" I know the engine will start) When I have the problem there is no clicking noise and my battery voltage gauge doesn't jump around. When I don't hear my glowplugs "cycling" I turn the key to the off position then turn it back to the run position. Sometimes I have to do this at least 5 times before the glow plugs will turn on.

What should I check? Is there anything I can do? Why does the "wait to start" lamp turn off even if the glowplugs didn't turn on? This problem usually only happens once or twice a day. Sometimes the glowplugs work fine. Could it be the controller?

Please write back with any help regarding my situation.

Thanks

 

Ditch that piece of ***** controller and install a toggle switch set up. Easiest way to do so is to run a momentary toggle switch up to an old ford starter solenoid connecting your battery leads to a secondary starter solenoid, and then from that solenoid to the plugs. This will ensure that you don't burn them up by accidentally leaving them on. Just count to about seven each time you hold the toggle up.