Well, I have been fighting electrical problems for quite a while now. From a swelled battery to a poor ground, I thought I finally had it worked out. Nope.

Got off work this evening and jumped in the cab, everything came on when I flipped on the key just fine. Turned the key to start and it made a half revolution before stopping. I have lost all electrical power, barely enough to turn on the dome light in the cab now.

I have no idea what is going on, tried to run jumper cables from my boss's truck but STILL not enough juice to get her going. Thank god it is a manual, pull started it and limped home.

When driving home, I noticed the rear anti lock light stays on constantly. Any time I touch the brake, the power dips terribly on my gauges (aftermarket voltmeter included).

Got home and started tracing wires around the engine bay. Strangely though, when I jumped in the cab and went to push in the clutch, my fat foot caught the brake and everything came back full power! Then as soon as I turned the key to start, same as before. A half revolution and then everything went dead again.

All of the wiring seems perfect, no melted links or anything...except this wire off my trailer brake:


(Yes, I need to do some more soldering, those locks are COMING OUT.)
That wire has a little wear on it, but not enough to break the insulation. Must have been rubbing against one of the pedals before dislodging completely. According to the guide I found online, that black wire to the controller is wired straight to the battery. It has to be it! But...where does it go?

PLEASE give me a hand here, I need her running by tomorrow morning!

 

IIRC that wire is for charging batteries on your trailer such as ones on a camper