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I have a 1987 F250 with the 6.9 N/A Diesel. When I started the truck Tuesday I got smoke from the right front side. I found I had melted the insulation off of a wire that I have since found is one of the wires that goes from the starter selnoid to the glo-plug relay. The question I have is when I tried to unplug the 8 wire connector, it was almost like it was glued and one of the connectors pulled out with the opposite side. I've seen others have this problem and was wondering, do they just use spade connectors or get an original type 8 wire connector? All of the wires aren't the same size so going back with a genaric connector won't work. One more question is why does Ford use 2 wires to go from the starter selnoid to the GP relay? Why not use a bigger wire?
Part of Fords wire size and number have to do with controlling how much current gets to the glow plugs because of voltage drop.
A while back I remember a user that rewired his glow plugs and used much larger wire.
He was getting enough power to the glow plugs that he had to shorten the glow time to keep from burning the glow plugs up.
That connector was starting to get corrosion in the glow plug power wire connections which caused it to make heat in the connector.
Enough heat was produced to melt the plastic together.