I got my new tranny in my 91 F250 7.3 and went to fire it up and no crank. All the lights, etc are working. I notice the connector for the glo plug harness is SMOKIN'! Turn key off and it's HOT there. So, try again with the same thing but I had to cross up the starter solenoid to get it started. Once started no smoke. SO, where do I begin? I've had this same problem before but re-wired the glow plug harness from another one. The wires to the glow plugs were bad and the connectors were all broke. Truck runs great once started but this really concerns me. Any hwlp will be GREATLY appreciated!

 

When you say the connector, are you talking the main plug in connector where the engine harness plugs into the chassis harness?

If so, the best thing is cut the glow plug supply wires, two large ones on one end of the connector as close to the connector as you can.
Then splice them together with a mechanical connector, I used a copper split bolt available at most hardware stores.

200 amps through that connector when the glow plugs are heating, a little corrosion on the contacts makes a lot of heat.

Make sure you tape it up well so it can not short out, and use caution when you are working on it, constant battery power in those wires.

 

Thanks!! Yes, it is the power side. I noticed in another post that a yellow wire connects to the gp relay. I have two yellow wires. do both connect to the same place?
This circuit doesn't have anything to do with the transmission does it? I wouldn't think so but with that mess of wires it's hard to tell.

Thanks gain!

 

The two yellow wires are power to the glow plug relay from the battery.
They have nothing to do with anything except the glow plugs.

The other wires in that harness go to the (IP fuel shut off solenoid, fuel heater, timing advance, fast idle and ignition signal to the glow plug controller), oil pressure sensor, water in fuel sensor, coolant temp sensor.
There is also a connector near the IP which I assume is for the FILP sensor for the E4OD tranny, but since I have a manual I am not sure about that part.

 

Thanks again!!! I think you hit the nail on the head with the connector being dirty. I'll cut the wires and do as you suggested. Just wanted to make sure there wasn't anything that goes to the trans. You are correct that the connector on the side of the pump goes tot he trans and it is the FIPL.

 

I have a picture of a melted connector somewhere, can't find it right now.

I went through that problem with my 86 several years ago.

Since yours is a 91, it is about the same age as my 86 was when I had the problem with it.

92, 93 and 94 owners, your time is getting close.
Inspect the engine harness to chassis harness connector and clean the connectors.
That may save you from problems shortly.