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Old 08-06-2013, 08:49 AM
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No crank, fuse #22 blown, #320 relay

2003 F350 with 6.0. I was cruising down the road when the engine died. Will not crank over. Fuse #22 is blown. Replaced it and it blew again as soon as the key was turned on. I pulled all the relays out, replaced #22 fuse, turned the key on. Inserted one relay at a time until the fuse blew: relay #302 = PCM. I've removed the air filter and battery and looked for any chaffed/pinched wires, but have not found anything in those areas. I crawled under the truck and looked at the wiring there and could not find anything.

Went to the other side and looked there. I did find a crack in the intercooler pipe hose connector that was blowing some oil out onto the a/c evaporator box and allowing the pipe to wiggle more than normal. The pipe has rubbed through the insulation on the ground cable, but that should not be a problem. No other wiring issues that I can see on that side.

Anyone have any suggestions on where to look next? Could it be a bad PCM? I sold my other 6.0, so I don't have a PCM to swap into this one (It was a 2007 and probably was different anyhow). Suggestions?
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Old 08-06-2013, 11:44 AM
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update

I have unplugged all three connectors from the PCM. I then tried a new fuse and installed the relay. It blew the fuse right away. So it looks like I have ruled out the PCM as the cause.

I also removed the fuse panel and I see it has a 2006 date stamp on it. The truck is a 2003, so I assume the previous owner replaced the fuse box at some point (the engine was replaced around that time frame with a reman). I will try unhooking all the harnesses from the fuse panel and plugging them in one at a time to find which harness is the culprit. Any other ideas?
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Old 08-06-2013, 12:56 PM
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Replace that chaffed ground, could cause problems down the road. Gonna go out on a limb, have u checked your fusible links? I believe one or more also protect engine control related to fuse 22.


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Old 08-06-2013, 06:10 PM
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Update #2

I disconnected all the plugs from the back of the fuse box and reconnected them one at a time. The one that caused the fuse to blow has 12 wires and is located on the lower right side of the fuse box.

Does anyone have a diagram to show where this plug leads to? I have the wiring diagram, but it doesn't show the connectors. Here is a picture of the back side(the outlet in question is the one in the corner):

Here is a picture of the plug (the one disconnected with the red stripe down the middle):

I put one lead of my digital multimeter to the frame of the dash and then inserted the other lead to each terminal of the plug. Four of the wires showed continuity: Black, black, blue w/yellow, green w/orange, tan w/ white stripe. The bundle of wires go to a bigger bundle and then go through the middle hole of the firewall. Once through the firewall, they then join up with another bundle and head for the pcm.

Here are the links to the wiring diagram (page 90 and 91): Powerstroke 6.0L Technical Intro Manual

Anyone have the "decoder" for the back of the fuse panel?
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Old 07-20-2014, 07:13 PM
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I hope you have got this fixed but just in case and for the benefit of others, the early 6.0L Powerstrokes were subject to wiring harness issues.

Fuse #22 serves four components: the PCM (which you ruled out) the Glow Plug Controller, The IPR (injection pressure regulator) on the turbo, and the EGR valve. It is possible that one of those is shorting out but more likely that the harness is rubbing through under the turbo.

Try using a resettable circuit breaker in place of the fuse during testing, disconnect the PCM, EGR, IPR and GPC and if it blows the breaker then go digging under the turbo.

Move the harness around and pay attention to the breaker, look for sharp turns in the harness around brackets and pinched harness where it routes under the turbo.

Good Luck!

Robert Grove
ASE Certified World Class Technician
Orange County Mobile Mechanic 714 709-4594 | We Come 2 U Mobile Auto Repair , Truck & RV Repair in Orange County
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Old 07-20-2014, 07:34 PM
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Thanks Robert. Yes the harness under the turbo was shorted out. I should have posted an update when I found the problem. It has run fine ever since, but now the torque converter has failed and it is parked in the shop again until I have time to swap in a new one.
Quote:
Originally Posted by RobertGrove View Post
I hope you have got this fixed but just in case and for the benefit of others, the early 6.0L Powerstrokes were subject to wiring harness issues.

Fuse #22 serves four components: the PCM (which you ruled out) the Glow Plug Controller, The IPR (injection pressure regulator) on the turbo, and the EGR valve. It is possible that one of those is shorting out but more likely that the harness is rubbing through under the turbo.

Try using a resettable circuit breaker in place of the fuse during testing, disconnect the PCM, EGR, IPR and GPC and if it blows the breaker then go digging under the turbo.

Move the harness around and pay attention to the breaker, look for sharp turns in the harness around brackets and pinched harness where it routes under the turbo.

Good Luck!

Robert Grove
ASE Certified World Class Technician
Orange County Mobile Mechanic 714 709-4594 | We Come 2 U Mobile Auto Repair , Truck & RV Repair in Orange County
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