94.5 psd: Will not Crank - Ford Powerstroke Diesel Forum
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Old 01-12-2008, 03:13 PM
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94.5 psd: Will not Crank

Hello,
I bought a 94.5 PSD about two weeks ago. Stock truck with 178K, New trannie, transfer case, Glo Plugs, some other misc stuff. 5 speed manual.

when I push the clutch in; the wait to start liight comes on bright, however the buzzer does no always sound. About 60-70 percent of the time when I hit the key it won't roll over. Nothing. I don't even hear a clunk that would indicate power is getting to the solenoid. Batteries have been cleaned and seem strong.

I replaced the Clutch pedal bushing and the problem seems worse.

Now: I reach up to the clutch cylinder rod and move the black plastic cylindrical housing around (where the little wire harness plugs in) (just aft of the firewall) and try again. The buzzer sings, wait to start is bright, and bingo it rolls and fires right up.

Any ideas??? Can I unplug that harness??? I read that 94.5's had a plastic clutch rod but this one is steel..

Any thoughts appreciated.

Brett
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Old 01-12-2008, 04:44 PM
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Hey brett, I believe that is a safety switch so you can't start the truck without pushing in the clutch. And as for disconnecting the harness, I don't think it will do the trick. Is there 2 or three wires? You might be able to jump the to see if the switch is bad.
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Old 01-12-2008, 06:01 PM
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Thanks for your thoughts.
That harness has 4 wires, two red, 1 white, 1 multi.....
The whole unit that harness plugs into slides on the clutch master cylinder push rod??? The problem seems to go away when entire housing is moved, not just the harness. almost like it has contacts on the firewall side of it.
I don't understand the clutch pedal/key buzzer relationship???

Brett
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Old 01-13-2008, 12:43 PM
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Anybody now if the clutch safety switch can be disconnected ( I.e. start in gear)

If not, has anyone replaced the clutch safety switch, 58$ at the local Napa. Not a bad price unless it has nothing to so with the problem???
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