I have a 96 PSD that has twin 5” stacks, an EDGE Programmer, 35 inch tires and a plow on it. I got it mainly to plow my lane and some neighbor's lanes. I live in the country with a half mile lane, as do some of the other locals. I got the truck in warm weather and it would start reasonably well then but the proof is when it gets COLD. Which it is now. My truck has been almost impossible to start now that it’s cold and even with the block heater plugged in, it takes forever to get runnin. I can start it after an hour of Block heating but when it gets below freezing, it takes a bout 3 hours AND the battery charger on it. Been readin lots here and someone here mentioned pulling the connectors for the GPs so I did that. I wanted to know what kind of connector it is so I could make up a test box to measure the currrent draw to see if I have any bad GPs, since I don’t have a digital ohmmeter. Guess I should have done that when it was warmer. Someone else here said that the 96 PSD has a 9-pin connector tho mine has a 5-pin connector, 2 of them for each valve cover. I pulled them all and found that one of the plugs on the wire loom has 2 burned pins on it. Well, the pins are probably still good but it is the plug body that is melted. The socket in the gasket isn't damaged. I’m sure I can repair the wireloom connector. I’d like to find one of those connector bodies so I can salvage the plastic that is burned away. Has anyone measured the current draw for the a single GP ? I know they are between 1 and 2 ohms which would figure out to anywhere from 12 down to 6 amps per GP. I want to be able to measure each glow plug so I can keep track of them. I’d also like to install a realtime monitor so I can keep track of them as my truck “ages”. BTW, it has about 200,000 on it. Any thoughts or ideas ? Roger

 

get the pigtail connectors to repair it, you dont want to try rigging it, lots of high voltage and amperage going through that connector. kunkels sells the repair kit, i think dorman makes it

 

Joe
What kind of high voltage are you talking about ? Is it 12 volts, 100 or 500 ?
I'm fluent with electricity so it doesn't bother me playing around with connectors and a soldering iron.
Roger

 

Joe is right. You can get repair ends at many parts stores now. The only ones I have seen come in a kit that comes with 2 repair ends, VC gasket and UVC harness. Still a good buy to have extra parts around.

The injectors run on 100-140 volts depending on what IDM you have. If its stock you are seeing about 100 volts. The Glow plugs are 12 volts but they also draw a good amount of amps.

 

I've called Advance and Autozone and neither of them had any clue as to what I was talking about. I called the FORD dealer and he was fairly clueless until I educated him. Then he came up with a part number and called it a shell but could not find any pins. I then called IH and he came up with pins only. Then another Ford dealer told me that the number I gave him was for a wiper motor. So I finally got the number for PowerstrokeShop in Indy and the 'board fella' wasn't in and the other fella didn't know what I was talking about. So another call tmw for th eplug with the pigtails on it. I tell ya, this diesel is making me wish I still had my gasser. We had lots of snow last nite and an ice storm that took down power lines so I was without power all day. And I couldn't start the truck so I couldn't plow my lane. Nothing worse than having a $12000 piece of sh8 sitting in your driveway blocking your car that always starts and goes thru most snow. Now that I know to avoid the hundred volts driving the injectors, I'll be careful there. The high current powering the GPs never hurt anyone so I'm not worried about that. But at least I know what's what there. Thanks for the info. RoGrrr

 

Parts from Napa
NAPAONLINE®
everything you could need. They might have to order it though.

 

Tim
Thanks for the update on the NAPA parts. I had called them earlier in the week and my man told me that he knew of nothing that would fit my needs. Now I can go to him and ask for a super-special price since I saved him all sorts of work.
I have been gathering all sorts of info but not what I really wanted.
I'll let you know how it turns out.
RoGrrr