Just Died, wont start? - Ford Powerstroke Diesel Forum
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Old 03-19-2012, 10:32 AM
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Just Died, wont start?

Need some help troubleshooting my 1996 F 350 crew. no mods. I was about 5 blocks from my house and the engine just stopped without warning ( in the middle of the intersection of course). Will crank freely will not fire. Check engine and wait to start lights do not come on. I had a similar issue a few years ago and the dealer replaced the glow plug wiring harness on each side. Could it be the same thing again. Any Ideas as to where to start the troubleshooting? First glance at fuses they were intact. Thanks in advance!
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Old 03-19-2012, 02:50 PM
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CHECK (DON'T replace just yet) maxifuse #22 under the hood. If it's blown, find the connector for the fuel heater on the fuel bowl (it's the middle one, vertically, IIRC; two wires, one of them red/green) and disconnect it, THEN replace the fuse. (If you don't disconnect the heater, it'll just blow the fuse again.) Then turn the key to RUN again and look for the WTS light. If it's on, go ahead and try to start it.
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Old 03-20-2012, 04:58 AM
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X2^^^^^^^^
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Old 03-22-2012, 01:49 PM
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Pulled the wire and replaced fuse. Truck started right up. Plugged the wire in fuse blew. How hard is the fuel bowl heater to replace? I know some feel it is not needed, though I would like to keep things original. Thanks for the help!!!!!!!!!!!!
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Old 03-22-2012, 06:03 PM
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It's easy to replace. Drain the fuel Bowl and remove the filter. Using a 7/8" crows-foot wrench, remove the black plastic standpipe (it is left-hand threaded!!!). Unplug the small spade connector on the inside of the fuel bowl and remove the heater plate. Put the new heater in and reassemble. Get a SD style replacement (the Dorman is supposed to work without any bowl modifications, but the Ford SD one usually does). Part numbers:

Fuel Heater Element
Old Style: (Ford) F5TZ-9J294-A (94-97)
New SD Style: (Ford) F81Z-9J294-AA, (International) 1831196C92, (Dorman) 904-210
(Ford/International requires some mods to fuel bowl, supposedly the Dorman does not)

Cheers!
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Old 03-22-2012, 08:57 PM
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"Original" is a nice idea, but it was designed for fuel that isn't even sold today. Not everything original about the truck is good; just look at the CPS and the glow plug relay.
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Old 03-23-2012, 06:13 AM
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Thanks for the help. What is a "SD" style of replacement? Can I still get the old style? Anything else I should be changing out at this time? Still not sure if I will replace the heater or not. What is the difference in the fuel? Will I have problems If I dont replace it? I live in Denver.
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Old 03-23-2012, 11:16 AM
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The SD (99+) style is a bit stouter and not prone to the problems that the 94-97 style did. You can still get the old one, but if you're going to spend the money, just get the Dorman unit and you probably won't have any further problems. All the old style ones I've had (or replaced) in my trucks have failed. Cheers!
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Old 03-27-2012, 02:20 PM
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aside from replacing the fuel heater i ive done evrything suggested i pulled the noted wire (i think) and im still blowing fuses. any other idea?
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Old 03-27-2012, 02:24 PM
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So you've disconnected the fuel heater, and the #22 is still blowing? Try disconnecting the red/green wire from the GP relay (make sure the terminal isn't touching anything else) and see if that keeps it from blowing. Relay could be shorted internally or something.
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