Posted this elsewhere and was told to drop it here for more input.

Hi all and thanks for any guidance.

I have to start by saying my participation is very limited here due to a very slow dial up which is all I can get and all the banners that cause the site to take for ever on every click!

I have an '02 Super duty with 7.3 diesel and 40K miles now.
Last winter I started having cold start problems.

I bought a DVD, Ford Factory Service Manual Data 2000-2003.

Too bad I am a bit challenged with software and can't find squat on this DVD.

Anyway, I think I might want to replace the glo plugs before the cold sets in.

No problems at all starting in above 30 degree temps and when it is below I plug it in a few hours before start up, have it on a timer.

I would like someone to point me to a thread here about this proceedure that might outline what parts to purchase and the how to to get it done.
I am no real mechanic but quite comfortable with tools and do most of my own maint.
Please let me know if special tools are needed or if there are pitfalls I might encounter doing this job. There might even be other factors causing hard cold starting but with just 40,000 miles I suspect the G plugs to be the problem.

All input is welcome and appreciated.

Thanks

Gary

 

I think the relay is the problem right now. All eight glow plugs don't burn out at once. The relay has a terrible track record. If you haven't already warmed the engine this morning, go out and jump the two big terminals with a big screwdriver on the rear most relay on the top of the engine for 30 seconds and then attempt a start. It would be best if you had a partner to turn the key as the glow plugs will cool off the second you open the circuit.

 

I pulled my factory glow plugs out at 70k to replace them and none of them were burned out so I don't think your's will be bad at 40k.
You'll find it's easiest to get at the glow plugs with a 1/4" drive deep 10mm socket. the rocker arms are too close to allow anything else in there.

 

is it a hard start when you have the Parking brake set and the tranny in neutral or park? if so you could also have a problem with the intake air heater. also what is the average temp during the cold months there. i know up here in AK your GPs typically last 2-3 years. but it also get 75 below zero without a wind chill

 

Will switch to a new GPR switch in the next couple days!

Truck is always parked on level driveway in Park and no P brake on.
Typical temps here in NY are rarely below -15 but most often +20 is when I experience problems.

I use fuel treatment, Cetane boost, durring cold months and all diesel sold after around November 1st is treated for cold weather or so I am told.

Truck does sit for long periods with zero use most of the time unless I need it for towing my trailer. This could be part of the problem but it always starts very easy durring warmer temps.

Gary

 

Did you try the screwdriver trick and it fired right up?

 

What are the cranking observations? Mine began to crank slower and slower, still started but took longer in colder weather. Replaced batteries and starts instantly now after WTS light goes out. Also, it has never cranked that vigorously since I bought the truck. Perhaps a free load test is in order.

 

if you set the parking brake when it is below 32 i believe and have it in park the intake heater will come on and it should start easier.

 

No screwdriver trick yet! I am at work and truck is home.

Batteries are fine and have plenty of juice with strong cranking.

Never heard the P brake trick but will also try this. Don't like leaving it on when truck is sitting for long periods but can easily set it before starting.

Great info and all is appreciated especially if I can avoid the glow plug change for at least another winter.

Can say for sure if my 7.3 was in -75 in Alaska right now, I would be stranded.
But, I would not want to be going anywhere any way! LOL

Gary

 

I think the air intake heater isn't designed to help with cold starts, but to help once the truck is already running (idling) and the air is cold. It helps avoid white smoke while idling when it's real cold. I think the glow plugs and engine block heater are all that help with the actual starting.

Gary, this thread should come in handy... from the Sticky at the top of the page:
https://www.ford-trucks.com/forums/4...ke-thread.html

 

Thats the thread I wanted ryaneverK2! Thank you.

I did get some great input above and will be doing some research this weekend if I can.

While we are on this subject, What the heck is the clunk I hear that sounds like a vent door slamming shut shortly after start up.

OK to you wise guys who can't wait to tell me its a vent door slamming shut!

What the heck is it and is it common.

Gary

 

your correct i was thinking of fast idle for the air intake heater the fast idle needs to be engaged and oil temp below 131 f

 

It is a vent door slamming shut!

Seriously, it really is, most likely. It is probably the blend door slapping shut... happens just after you start it. Try turning your climate system to OFF and see if it does it still. But yes it's QUITE common, and generally accepted to be the blend door closing.

 

Must be good ears here! Didn't even need a doctor for this diagnosis!

Have to check dials because I am not sure my climate control has an Off position. Don't drive it much but sure do love it!

Thanks again

Gary

 

No problem, Gary.

Yeah it will have an OFF position, where the switch is straight up center. When it's in OFF, the outside air is shut off, and the fan does not blow at all. Any other setting, the fan will blow on low or whatever it's set to. Actually it'd be worth reading in the owners manual about the different climate settings... I hadn't been in a car/truck with settings like my truck before I got mine, so I learned some stuff. For example, the A/C runs when it's in the defrost mods, to help get the humidity out of the air. Also, it uses outside air on all settings but OFF and Max A/C. It also recommends that when you park the truck overnight or for any length of time, to leave it on any setting other than Off or Max A/C, so that the truck has outside air that can flow freely in/out, to let the truck "breathe" and not get old stale air or moisture trapped in there.