Glow plug replacement day!
 

Well guys, after noticing only a 3-4 second glow time in sub zero temps, I finally got under the hood with my test light to see how many glow plugs I had out.

Turns out, at least 2 were bad and 1 was on its way. Figured I would play it safe and ordered 4 sealed Motorcraft ZD9's off ebay. A good deal I couldn't pass up for $34 total.

Sprayed some PB blaster on the plugs and let it sit for two days before the glow plugs arrived. Today was the day though and I got under the hood to finally replace em.

Now, I was told the previous owner only put in motorcraft parts and babied the thing... BULL####!! :-X09

I cringed when I pulled the back passenger side plug to discover...a champion. Now I figured this was done by the shop that did my valve seals...until I pulled the rest on the passenger side.

So far: 1 champion and 3 autolites. Thank GOD none of them were swollen...but three of them had noticeable deformation.

Out of plain curiosity I pulled the first two on the driver's side (tested good but what the hell) and found another champion and autolite. Didn't even have to pull the rest before another 4 genuine zd9s were on order...

Here is a picture of the first POFS champion I pulled next to a genuine beru:
http://i26.photobucket.com/albums/c1...s/CAM_0016.jpg

Here is a shot of the slight deformation on one of the autolites:
http://i26.photobucket.com/albums/c1...s/CAM_0018.jpg

Two pieces of autolite garbage:
http://i26.photobucket.com/albums/c1...s/CAM_0020.jpg

And finally, the RIGHT plug in the RIGHT place:
http://i26.photobucket.com/albums/c1...s/CAM_0017.jpg

Now after this was finished, I figured I would turn the key to see how it performed...and WOW! I got a whole 18 second glow time! The truck had been sitting in sub zero temps and today was a warmer day at 20*F but it cranked right over no problem.

I honestly had no hopes that it would start...otherwise I would have caught it on camera!

I'm very impressed with the old girl after today and can't wait to get the rest of the Motorcraft plugs in it. :-dancing1

-Dave

I know how you feel. I just left Ohio after spending 2 weeks in all the snow and cold tempratures. The warmest it got was 31 the day before I left. Twice it got to 1 degree and I waited till it was 5 above before I started the 1987 6.9. She never failed to start, the first time I turned the key. I will have to admit I had put 8 motorcraft/beru gp's in, a new gp controler and made brand new battery cables to hook up to the 2 new batteries within a month of going to Ohio.

Sounds like you dodged a couple bullets. Nice work!

Finally found a worthy video editor and went to work!

Below are the before and after starting videos. Enjoy! Comment & Rate if you wish.

Before replacement:
YouTube - Ford Diesel IDI cold start

After:
YouTube - Ford Diesel IDI cold start: take 2

(Sorry, embedded links seem to not be working, so I supplied the links)

WOW what a difference. I need to do mine, but it can wait till it warms up some. Thanks for posting the vid.:-jammin

There's the real proof in the pudding! What a difference!

Right on! just put new gps and relay in mine. would not start at all without either. Now the wait to start runs about 10 sec and fires on at least the third turn. GOTTA LUV THESE OLD IDI'S !!

Loving the old truck more and more with the time I spend fixing the little things in it. Still impressed that it fires so well in the cold now :-headbang

I need to get a video of mine, at 30 degreees with 6 AC DELCO8g glowplugs mine lights off on the first turn of the engine, and 20-25 it turns over 2-3 times, thats with 6 plugs

yup,the IDI starts very easy when everything is kept up and totally bad when they're not.
it doesn't take much to get them up to par.most cases they just need some love given to the battery cables(cleaning or replacement),and some new motorcraft plugs.
sounding good there Dave.

I went through that a few months ago. I went to change 2 dead plugs only to find they were autolites. Ended up changing all 8 instead. It's a world of difference.

Well, its been a couple weeks now and the plugs still seem to work great! Way easier starts in the mornings and no more extended cranking.

But I did notice something when I started it up today. The usual clicking sound of my glowplug controller has gone away.
After starting up the truck, it used to click on and off for a about a minute. Also, my voltage meter isn't showing a drop anymore as it usually would when the controller would click.

Could this be a potential problem or are the glowplugs just not needing to cycle like it used to once the truck is running?

I pulled the front two plugs to check them and they are doing just fine...could I just be worrying over nothing?

-Dave

Mine is the same way, I think it's because of the bad GP's that it clicked so much. I have an LED wired to the power side of my controller so I know the plugs are on. when I turn the key, they come on. The WTS light will shut off after 10-15 seconds and I will start the truck but the glow plugs will remain steady/on until about 5 seconds after the truck is running. Sometimes they will pop on again 1 or 2 times after for a second or two.

I would say you are worrying over nothing, The new plugs probably are showing the controller the right resistance and the after glow is not needed, this may change during a real cold spell.

Love it when they work like you plan. My controller(another thread to come) is acting really wierd lately though. It isnt excessively cold, the start time is still on right away mode but it clicks erratically when the high idle shuts off. Check it out if you have a thought.