Glow plugs and controller install
Thread Starter
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Junior User
Joined: Jun 2004
Posts: 65
Likes: 0
From: Tampa Bay, Florida
Hi Guys,
I found my answer. I installed the wellman glow plugs today with the new controller. Truck started right up. I use the truck only 5 days a month. The truck did not run and I needed to move it. I tried locating motorcraft glow plugs today and all my local parts stores carry only autolite, advance, autozone even napa. Shame on napa. Anyway. I will keep an eye on the plugs and when I have time. I will go to FORD and get motorcraft, then I will replace them. But for the time being, I will use the Wellman plugs.Thank you all for the warnings and info. I am sorry to hear the problems you have had in the past. Take care.
Joe Flash man
I found my answer. I installed the wellman glow plugs today with the new controller. Truck started right up. I use the truck only 5 days a month. The truck did not run and I needed to move it. I tried locating motorcraft glow plugs today and all my local parts stores carry only autolite, advance, autozone even napa. Shame on napa. Anyway. I will keep an eye on the plugs and when I have time. I will go to FORD and get motorcraft, then I will replace them. But for the time being, I will use the Wellman plugs.Thank you all for the warnings and info. I am sorry to hear the problems you have had in the past. Take care.
Joe Flash man
Methanoholic
Joined: Mar 2009
Posts: 6,442
Likes: 8
From: Maine (NorCal Native)
Honestly, I looked over the specs on the Motorcraft/Beru GP's our era trucks use (ZD1A and ZD9) but I really do not remember what the voltages are.
However, Ford/IH in their infinite wisdom used wire thats too small thus the Glow Plug harness voltage losses are heavy.
What causes tips to explode ... Cheap materials, Poor manufacturing processes, Over heating, Moister inside them, I dunno know for sure, I'm sure any one of several things can cause it and I'm sure several do.
I would suspect if they had moister in them when built they would explode on first use, the Bosch GP's I had in my 6.9 were in there about 1 year before all 8 of them swelled with NO signs of controller failure.
-Enjoy
fh : )_~
However, Ford/IH in their infinite wisdom used wire thats too small thus the Glow Plug harness voltage losses are heavy.
What causes tips to explode ... Cheap materials, Poor manufacturing processes, Over heating, Moister inside them, I dunno know for sure, I'm sure any one of several things can cause it and I'm sure several do.
I would suspect if they had moister in them when built they would explode on first use, the Bosch GP's I had in my 6.9 were in there about 1 year before all 8 of them swelled with NO signs of controller failure.
-Enjoy
fh : )_~
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
Generally any glow plug can swell.
This is a CYA statement that says if you use their glow plug and it swells, they are not responsible for the damages/expenses.
They may have developed most of Fords glow plugs, Autolite, Champion, Bosch, Wellman numbers that "Fit" the IDI engine.
They all fail and generally swell when they do.
Just be aware if you have to take your truck to a shop to pull a head and remove a stuck swollen glow plug you are looking at about 22 hours shop time and about 400 in parts.
This is a CYA statement that says if you use their glow plug and it swells, they are not responsible for the damages/expenses.
They may have developed most of Fords glow plugs, Autolite, Champion, Bosch, Wellman numbers that "Fit" the IDI engine.
They all fail and generally swell when they do.
Just be aware if you have to take your truck to a shop to pull a head and remove a stuck swollen glow plug you are looking at about 22 hours shop time and about 400 in parts.
Methanoholic
Joined: Mar 2009
Posts: 6,442
Likes: 8
From: Maine (NorCal Native)
If it doesn't destroy the motor ...
Flashman, We are only trying to save you from the headaches we ourselves have learned by experience, that is all! We regulars are here because we like to help people and that's all we are trying to do is help!
Yea, I'm pushy about the Glow Plugs because I have been bitten!
Sorry, but It cost me a motor at a very very bad time and if my pushing saves ONE person from getting bitten it's worth it to me.
-Enjoy
fh : )_~
Flashman, We are only trying to save you from the headaches we ourselves have learned by experience, that is all! We regulars are here because we like to help people and that's all we are trying to do is help!
Yea, I'm pushy about the Glow Plugs because I have been bitten!
Sorry, but It cost me a motor at a very very bad time and if my pushing saves ONE person from getting bitten it's worth it to me.
-Enjoy
fh : )_~
Thread Starter
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Junior User
Joined: Jun 2004
Posts: 65
Likes: 0
From: Tampa Bay, Florida
Hi Fellas,
I understand that you are trying to steer me in the right direction.The truck is going to sit for a few weeks now anyway. I only use it to haul large loads.(55 gal drums) I have a gasoline van that I use for my regular deliveries.This will give me some time to locate Motorcraft glow plugs. I have done heavy work on vehicles all my life. Engines, transmissions rebuilds etc. But as I get older, I try to avoid doing heavy work. I break my back enough with my business everyday. I believe you all and appreciate the info. I have been bitten on a few things too and learned my lesson. I will keep you posted when I get the Motorcraft gps. Thanks.
Joe Flash man
I understand that you are trying to steer me in the right direction.The truck is going to sit for a few weeks now anyway. I only use it to haul large loads.(55 gal drums) I have a gasoline van that I use for my regular deliveries.This will give me some time to locate Motorcraft glow plugs. I have done heavy work on vehicles all my life. Engines, transmissions rebuilds etc. But as I get older, I try to avoid doing heavy work. I break my back enough with my business everyday. I believe you all and appreciate the info. I have been bitten on a few things too and learned my lesson. I will keep you posted when I get the Motorcraft gps. Thanks.
Joe Flash man
Junior User
Joined: Jul 2010
Posts: 72
Likes: 0
From: Yuba City, CA
Anti seize is a good move, swelling occures with using any type of starting agents. I have changed my GP's many times, always use Autolite, and have never had a tip breakage issue. As of now, my 1990 F250 4X4 7.3 IDI has 1,145,062 miles on it. I think it is getting tired, so I am building a 1994, 20 over big pin, with an ats turbo. I will see if this brings it back to life.
Methanoholic
Joined: Mar 2009
Posts: 6,442
Likes: 8
From: Maine (NorCal Native)
Flashman, Sorry, I thought I posted a link to a low cost source for Motorcraft/Beru ZD9 Glow Plugs.
DieselFiltersOnline.com ZD9 Glow Plugs
Sometimes you can find a better deal other places like eBay, this is a consistent price/source.
BTW, Beru's are made in Germany.
If you're interested in getting rid of your old dead controller, I'd like to get my hands on it, I'm looking for one so I can dissect it.
-Enjoy
fh : )_~
DieselFiltersOnline.com ZD9 Glow Plugs
Sometimes you can find a better deal other places like eBay, this is a consistent price/source.
BTW, Beru's are made in Germany.
If you're interested in getting rid of your old dead controller, I'd like to get my hands on it, I'm looking for one so I can dissect it.
-Enjoy
fh : )_~
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
twboggess,
Good luck with that 20 over 7.3 turbo.
Cylinder walls will be paper thin, so you may get 20 thou out of it before it cavitates.
I tried a reman 7.3 turbo, had a 20 over bore.
29,000 miles and I went through 3 motors in about 14 months.
Thank god for a warranty is all I can say.
They sent me a fourth, I tore it down while it was still bolted to the shipping pallet and refused to install it.
Warranty was running out, if the next one blew it would have been 7,000 dollars out of my pocket.
So I bought a salvage yard 6.9, rebuilt it myself, did a few mods, put 25 PSI of boost to it and here it is 5 years later still going strong.
Good luck with that 20 over 7.3 turbo.
Cylinder walls will be paper thin, so you may get 20 thou out of it before it cavitates.
I tried a reman 7.3 turbo, had a 20 over bore.
29,000 miles and I went through 3 motors in about 14 months.
Thank god for a warranty is all I can say.
They sent me a fourth, I tore it down while it was still bolted to the shipping pallet and refused to install it.
Warranty was running out, if the next one blew it would have been 7,000 dollars out of my pocket.
So I bought a salvage yard 6.9, rebuilt it myself, did a few mods, put 25 PSI of boost to it and here it is 5 years later still going strong.
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Elder User
Joined: Jul 2010
Posts: 610
Likes: 0
From: Sequim. WA
GP Controller
There is no way a controller can have anything to do with the voltage to the GP.
The "controller" controlls the opening and closeing of the relay. Voltage goes straight through the relay to the GPs. what ever voltage your battery has is what is going to the GP.
Have fun!
The "controller" controlls the opening and closeing of the relay. Voltage goes straight through the relay to the GPs. what ever voltage your battery has is what is going to the GP.
Have fun!
Post Fiend
Joined: Jan 2000
Posts: 5,330
Likes: 17
From: Dryden, ON, Canada
I have had good luck with the dual coil wellmans on a 6.9 system, other than one failure under warranty 5 years ago, and a drunken friends trying to start my truck issue, I've had no issues with my truck, nor the other 2 I've installed them in(4+ years in both,) and in my truck I have been known to burn them 20-30 seconds on a -30 day. I've also had good luck with the dual coil PSD ones.
However, for a 7.3 style system, Beru plugs are the only way to fly, a dual coil plug won't work with the system, and all the aftermarket stuff just doesn't live.
I've even had swelled Berus to deal with, last PSD I did had the last plug I changed stick, rearmost on the pass side in an OBS... that was FUN...
However, for a 7.3 style system, Beru plugs are the only way to fly, a dual coil plug won't work with the system, and all the aftermarket stuff just doesn't live.
I've even had swelled Berus to deal with, last PSD I did had the last plug I changed stick, rearmost on the pass side in an OBS... that was FUN...
Elder User
Joined: Mar 2008
Posts: 912
Likes: 0
From: Marianna, Florida USA
Well then this guy is incorrect about the voltage for the 7.3 IDI glow plugs? I keep asking the same question and Marianna seemed to answer part of it. What swells a glow plug? Improper voltage causing heat? Where does this improper voltage come from. A bad glow plug controller?
Joe Flash man
Joe Flash man
Improper voltage can swell a GP, but the greater risk is too much time at voltage. There is no control over the temperature with a single coil GP. The second coil in a Dual Coil GP is in series with the heating coil. As it heats, the resistance increases, reducing the power input thereby controlling the temperature. Overvoltage can occur anytime a dead battery is jumped with a device that has an open circuit voltage excessively over 12V. Don't jump with a 24V system or a booster that can put out several hundred amps. Let the battery charge at least until it has enough reistance to pull the available voltage from the booster somewhere 12V. Dead batteries, as I'm sure you are aware have no resistance since all of the available H2SO4 is reacted with the lead leaving nothing but water in the electrolyte.
Senior User
Joined: Jul 2010
Posts: 109
Likes: 0
Dual Coil GP? What? Where? How?
I put the AC brand in my 6.9 before I found this place. While my start issues are gone, it seems that I might be on barrowed time. My controller ('86) works fine. But I used to have huge voltage spikes after cold start ups until the GP controller saw the correct temperature. I fixed that. One of the GPs had cooked the connector off and it was shorting. That caused the voltage regulator to go full voltage. I blew 6 head lights before I figured that one out as it only happened when the GP wire touched.
So, back to the duel coil GPs...
I put the AC brand in my 6.9 before I found this place. While my start issues are gone, it seems that I might be on barrowed time. My controller ('86) works fine. But I used to have huge voltage spikes after cold start ups until the GP controller saw the correct temperature. I fixed that. One of the GPs had cooked the connector off and it was shorting. That caused the voltage regulator to go full voltage. I blew 6 head lights before I figured that one out as it only happened when the GP wire touched.
So, back to the duel coil GPs...
Methanoholic
Joined: Mar 2009
Posts: 6,442
Likes: 8
From: Maine (NorCal Native)
Some Beru Glow Plug specs ...
Type ............................ GV 823 (ZD9) .... GV 835 (ZD1)
Order Number ............. 0 100 271 101 ... 0 100 271 102
Thread Size ................. M 10 x 1.00 ....... M 10 x 1.00
Length of Glow Plug ... 81 ...................... 78.5
Reach ......................... 28 ....................... 27.5
Hex ............................. 9.5 ..................... 9.5
GP Nm ........................
Connect max. Nm ......
Volts ........................... 10.5 ................... 10.5
Amps ..........................
Seat ............................ Conical .............. Conical
Connection ................. Pin ..................... Blade
Have not found wattage or amperage yet.
-Enjoy
fh : )_~
Type ............................ GV 823 (ZD9) .... GV 835 (ZD1)
Order Number ............. 0 100 271 101 ... 0 100 271 102
Thread Size ................. M 10 x 1.00 ....... M 10 x 1.00
Length of Glow Plug ... 81 ...................... 78.5
Reach ......................... 28 ....................... 27.5
Hex ............................. 9.5 ..................... 9.5
GP Nm ........................
Connect max. Nm ......
Volts ........................... 10.5 ................... 10.5
Amps ..........................
Seat ............................ Conical .............. Conical
Connection ................. Pin ..................... Blade
Have not found wattage or amperage yet.
-Enjoy
fh : )_~
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