Replaced glow plug controller, NO START!! - Ford Powerstroke Diesel Forum
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Old 02-11-2012, 06:02 AM
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Replaced glow plug controller, NO START!!

Please help!! 1996 7.3 F250. No mods. I recently replaced my glow plugs, UVCH's, and glow plug controller. Also did a fuel bowl rebuild while I was under the hood-all new gaskets, orings, etc. Here's the problem: put everything back together and now my truck won't even turn over. The electrical is going crazy! Looks like I have the GPC wired correctly but when I turn the ignition on, the dash lights flicker like crazy (wait-to-start/check engine) and the inside buzzer even sounds funny. When I try to start the truck, everything goes dead for a few seconds, then back to crazy. The GPC is clicking sporadically and the relay/fuse box under the hood is clicking FAST. Sounds like something's gonna blow! I did wash down the motor 2 days ago. Maybe got some electrical stuff wet? Whatever it is, I can't get the motor to turn over. Once the starter engages, the electrical goes dead, then goes crazy. Any ideas??
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Old 02-11-2012, 06:22 AM
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Check your batteries and all connections.

Low voltage can cause your truck to go nuts. Water in the power distribution box can too.
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Old 02-11-2012, 06:38 AM
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check the batteries?
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Old 02-11-2012, 09:54 AM
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Have the batteries load tested independent from each other (all cable disconnected from both). If one battery is bad, replace them both. My brother-in-law's truck had very similar symptoms when one battery shorted internally. Cheers!
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Old 02-11-2012, 03:53 PM
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Thanks guys. Batteries tested good. Both are less than a year old. Looks like water in the power distribution box. Will it dry out over time? Should I leave the batteries disconnected?
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Old 02-11-2012, 04:52 PM
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Blow everything out with compressed air and let it dry overnight. Then see what happens.
Pull the relays out in the distribution box and make sure there is no water bridging the relay contacts.
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Old 02-12-2012, 02:21 AM
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Get lots of compressed air and do as state above....blow everything out. Disconnect every connector and give it a good shot of air and make sure they're good. Who knows where water could have gotten with trucks this old.
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Old 02-14-2012, 05:40 PM
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Thanks for the help, guys. Dried out the distribution box. 2 days later, fired right up! Thanks again.
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Old 02-14-2012, 06:32 PM
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glad to help. you may want to pull it apart and reseal it to keep water out in the future
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Old 02-19-2012, 12:59 AM
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My '95 F250 Powerstroke had issues very similar even 'after' the electrical gaskets were replaced, the glow plus, synchronizer, relay... all electrical going off in the middle of traffic, dead, absolutely dead. Diodes went out so no more cruise control, speedometer went out, a lot of different strange things.

it turned out to be, wierd enough, the fuel heater pad on the bottom of the fuel filter housing or something like that, was shorting everything out.
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