Notices
Pre-Power Stroke Diesel (7.3L IDI & 6.9L) Diesel Topics Only

need advice for wiring problems

Thread Tools
 
Search this Thread
 
Old Dec 26, 2009 | 06:06 PM
  #1  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
need advice for wiring problems

i recently bought a new project truck its a 92 7.3 its had a motor swap for unknown reasons the owner gave up on it. so ive got it running but only with ether I have checked the gp's and their all good .relay gets no power with key forward to the brown wire so no juice to gp's. swapped out relay with an extra that came with the truck and the harness connector on the drivers fender started smoking. also i noticed when i bought it that the gp relay maxi fuse was missing. I'm stumped anyone had this sitution before. I guess I just bought someones wiring nightmare
 
Reply
Old Dec 26, 2009 | 06:12 PM
  #2  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
by the way its the two big yellows that are smoldering. the ones that go to the gp relay
 
Reply
Old Dec 26, 2009 | 06:12 PM
  #3  
Franklin2's Avatar
Franklin2
Moderator
25 Year Member
Photogenic
Community Builder
Community Influencer
Joined: Jan 2001
Posts: 56,999
Likes: 2,746
From: Virginia
Club FTE Gold Member
Do you like the idea of manually controlling the glowplugs with a pushbutton in the cab?
 
Reply
Old Dec 26, 2009 | 06:14 PM
  #4  
Franklin2's Avatar
Franklin2
Moderator
25 Year Member
Photogenic
Community Builder
Community Influencer
Joined: Jan 2001
Posts: 56,999
Likes: 2,746
From: Virginia
Club FTE Gold Member
Originally Posted by mystic04
by the way its the two big yellows that are smoldering. the ones that go to the gp relay
If they are smoking at the plug on the pass side fenderwell, then that's a common problem, the plug is burnt up. I cut the yellow wires out of the plug, put ring connectors on all 4, and then bolted them together to bypass the plug.
 
Reply
Old Dec 26, 2009 | 06:44 PM
  #5  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
they are coroded all to hell but my question is. is there a problem before the connector or is it the gp relay thats grounding out to make this happen ?
 
Reply
Old Dec 26, 2009 | 07:35 PM
  #6  
starmilt's Avatar
starmilt
Post Fiend
Joined: Oct 2007
Posts: 10,501
Likes: 5
From: Faibanks Ak.
If they were corroded that may be what caused it to smoke a bad connection will heat up seriously under the amp load of the glow plugs.
 
Reply
Old Dec 26, 2009 | 07:42 PM
  #7  
Franklin2's Avatar
Franklin2
Moderator
25 Year Member
Photogenic
Community Builder
Community Influencer
Joined: Jan 2001
Posts: 56,999
Likes: 2,746
From: Virginia
Club FTE Gold Member
The glowplugs draw a lot of amps, so the problem is usually at the connector. I believe the yellow wires have fusible links were they connect at the starter relay, so they will blow if something is shorted. Sounds like the glowplugs are trying to work, if you get the connection fixed.
 
Reply
Old Dec 26, 2009 | 09:31 PM
  #8  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
ok i bypassed the connector on drivers fenderwell used yellow butt connectors on the two yellow wires. now it doesnt smolder there it smolders at the relay coil but it will start now is this normal it doesnt seem that it should smolder and stink
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

 Verdad Gallardo
story-1

Top 10 Fords at 2026 Carlisle Ford Nationals

 Joe Kucinski
story-2

3 Best / 3 Worst Parts of Modern Ford Ownership

 Brett Foote
story-3

10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

 Pouria Savadkouei
story-4

Every 2026 Ford Engine Explained

 Brett Foote
story-5

10 Ugly Ford Trucks That We Still Kinda Love

 Joe Kucinski
story-6

10 Things Every Truck Owner NEEDS (2026 Edition)

 Michael S. Palmer
story-7

Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

 Verdad Gallardo
story-8

Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

 Joe Kucinski
story-9

2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

 Brett Foote
Old Dec 26, 2009 | 10:53 PM
  #9  
Dave Sponaugle's Avatar
Dave Sponaugle
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Club FTE Silver Member

You may just have oil on the resister on the controller.

200 amps draw when the glow plugs are heating, that makes things get warm.
 
Reply
Old Dec 27, 2009 | 07:57 AM
  #10  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
ok she fired up last night but made an awful clanking noise so i shut it off. my guess is some cylinders arent firing due to dead glow plugs and or bad connectors. my connectors are falling apart as it is. thanks for all the help so far guys.
 
Reply
Old Dec 27, 2009 | 01:03 PM
  #11  
Dave Sponaugle's Avatar
Dave Sponaugle
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Club FTE Silver Member

What transmission do you have?
 
Reply
Old Dec 27, 2009 | 04:42 PM
  #12  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
e4od, got it running today, it takes a bit for all cylinders to fire for some reason.but when you start it with ether it starts smooth. i tested all glow plugs and they were good. so i drove it around for a while to get her hot it was fine under acelleration but idling it would sputter once in a while. maybe it just needsa to be run. I drained both tanks when i bought it put 5 gal of fuel in each tank and split a whole bottle of diesel kleen between the two tanks plus new filter and return line kit. So i dont think its a injector problem. thanks again for all the help so far
 
Reply
Old Dec 27, 2009 | 07:25 PM
  #13  
Dave Sponaugle's Avatar
Dave Sponaugle
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Club FTE Silver Member

If you used the test light method, some of the glow plugs may not be heating as well as the others are.

As for the sputter, probably needs driven some with a couple heavy doses of fuel treatment until everything gets clean and lubed up.
 
Reply
Old Dec 27, 2009 | 10:42 PM
  #14  
mystic04's Avatar
mystic04
Thread Starter
|
Freshman User
Joined: Dec 2007
Posts: 37
Likes: 0
well I do not own a test light so i figured theoreticaly it would be the same to put the positive lead of my multimeter in the positive terminal of a battery and touch the negative to the terminal of each glow plug and it showed the batteries volts perfectly for all of them. I hope I'm right anyway
 
Reply
Old Dec 27, 2009 | 11:39 PM
  #15  
Dave Sponaugle's Avatar
Dave Sponaugle
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Club FTE Silver Member

If the multimeter is a decent one.
Remove the wiring connector, set the multimeter to ohm's, touch one lead tot eh glow plug electrical terminal and the other to the glow plug lower body (hex nut).

.5 to 1 ohm resistance is ideal.
Repeat for all 8 glow plugs.
 
Reply



All times are GMT -5. The time now is 01:14 PM.

story-0
This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

Slideshow: The VelociRaptor Expedition gains a lift, upgraded suspension, Brembo brakes, and trail-ready equipment while retaining the stock 440-horsepower EcoBoost V6.

By Verdad Gallardo | 2026-06-12 11:01:55


VIEW MORE
story-1
Top 10 Fords at 2026 Carlisle Ford Nationals

Slideshow: Top 10 Fords at 2026 Ford Nationals

By Joe Kucinski | 2026-06-09 11:10:08


VIEW MORE
story-2
3 Best / 3 Worst Parts of Modern Ford Ownership

Based on years of owning multiple modern Ford products.

By Brett Foote | 2026-06-09 10:53:36


VIEW MORE
story-3
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

SPONSORED: From muddy boots to rain-soaked cargo, these upgrades address some of the most common frustrations Ford truck owners face every day.

By Pouria Savadkouei | 2026-06-08 18:50:34


VIEW MORE
story-4
Every 2026 Ford Engine Explained

Here's everything you need to know about every Ford engine available for the 2026 model year.

By Brett Foote | 2026-06-05 12:58:01


VIEW MORE
story-5
10 Ugly Ford Trucks That We Still Kinda Love

Slideshow: 10 ugly Ford trucks that we still kinda love.

By Joe Kucinski | 2026-06-03 09:51:16


VIEW MORE
story-6
10 Things Every Truck Owner NEEDS (2026 Edition)

Slideshow: the best gifts for dads & grads

By Michael S. Palmer | 2026-06-03 15:43:58


VIEW MORE
story-7
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.

By Verdad Gallardo | 2026-06-03 11:38:36


VIEW MORE
story-8
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

Slideshow: 10 most expensive Ford trucks ever sold on Bring a Trailer.

By Joe Kucinski | 2026-05-27 16:24:34


VIEW MORE
story-9
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

Here's everything that has changed for the latest model year.

By Brett Foote | 2026-05-27 16:17:28


VIEW MORE