Started by hooking everything up to another battery, including the light and the relay. It all worked great. Then made jumper wires for each terminal on the relay and joined them to their proper holes in the fuse box. The relay buzzed. I then removed the ground side of the coil on the relay and put it on a known good ground. The buzzing did not happen when I did this. Leads me to believe that there is a short in the circuit that grounds the coil in the relay. My friend who works for Ford came by and took a quick look for me. He said that most likely the problem is coming from inside the bottom of the fuse box, where it is all corroded and damp. I put the relay back in, and there was the faint sound our water on electricity. The it stopped, and everything is working fine now. Wonder if it will stay that way? I think that I will leave it alone for now, and come back to it when it acts up again.....Wait........Ok, just went and checked on it. It has been 1 1/2 hours, and no buzzing. I'm sure it will come back at the least convenient time though.
Even if it does come back today, I am just going to pull out the relay and deal with it another day. It is Sunday afternoon, and I don't want to have spent my whole weekend messing around with the electrical on my truck.
I'll keep you posted.
Karma.

 

The gem grounds the relay so Its either a bad connection or the gem or the door switches Or wires to the switches...nothing to do with the fuse box as there are no grounds there..The heater has nothing to do with the gem.


Dick

 

Well, after my last post, the buzzing came back. I pulled the relay, and just lived without an interior light for the last couple weeks. I have appreciated everyone's help with this issue, but was convinced that it WAS the fuse box itself that was causing the problem (it was REALLY rusted inside). An auto wrecker in Nanaimo got in a 1999 SD and I had them pull the fuse box (and some other stuff) for me. It arrived yesterday, and I installed it right away. So far so good. I would like to take apart the old one and post a picture, but I may wait a few weeks just to make sure that I have fixed the problem. I think that others on the forum might be interested to see what it looked like inside the old fuse box. I will keep you posted.
Thanks again for all your help everyone. It is very, very, very much appreciated.
Karma

 

Oh Yeah, I paid $100 for the fuse box, instead of $400 from Ford.