Did something stupid cranks no start - Ford Powerstroke Diesel Forum
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post #1 of 21 Old 12-22-2018, 09:54 PM Thread Starter
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Few months ago I added the western plow relay to my truck. Only I accidentally replaced the AIH relay with it. Yes, yes I know.... picked up trailer, 20 min later truck cranked no start and got smoke from a wire on the actual glow plug relay.

Anyone got good info on how to proceed?

Pic shows the wire that gets so hot it melted a plastic cover on it. I figured order a new glow plug relay but the wire that gets super hot has some sort of butt connector or maybe fuseable link.

I removed the western plow and put back the aih relay I removed and it started then I parked to check trailer and load and crank no start with wire on big post of oem glow plug relay getting super hot again.

Yes I know I did something dumb and I apologize. What would you check for besides just a new gpr?

Thanks.


Ps the picture shows the plow relay in place of the AIH relay but I have swapped the old relay back in.
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Last edited by JustinOOO9; 12-23-2018 at 11:45 AM.
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post #2 of 21 Old 12-23-2018, 12:37 AM
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well, it sounds like some of the wiring was heavily stressed, I'd want to replace the fried wires and their connectors pins. afaik, you can get the pins for all the connectors, its just kinda complicated to figure out just which pins you need and be sure to use the correct gauge wire, and secure it alongside the harness to bypass the fried wires inside.. Or, you could just get a harness of a JY truck, and swap the whole thing. I dunno.

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post #3 of 21 Old 12-23-2018, 07:06 AM Thread Starter
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Does anyone know if they sell a harness for the glow plug system outside the uvch or is it part of the main harness?

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post #4 of 21 Old 12-23-2018, 07:58 AM
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Originally Posted by JustinOOO9 View Post
Does anyone know if they sell a harness for the glow plug system outside the uvch or is it part of the main harness?
Maybe Corey knows. @[email protected]

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post #5 of 21 Old 12-24-2018, 06:25 AM Thread Starter
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Anyone know if the harness that the gpr wires feed into also runs the icp/ipr/pcm stuff? Wondering once I replace the relays I probably burnt up what else to check for.

No codes, icp and ipr are good cranking but if the truck sits overnight it will run just lopes pretty good. No unusual smoke.

Would checking the new oem uvch be good? Wondering if I may have burnt one of them
Up when I messed up the gpr?

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post #6 of 21 Old 12-24-2018, 08:20 AM
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Originally Posted by JustinOOO9 View Post
Does anyone know if they sell a harness for the glow plug system outside the uvch or is it part of the main harness?
all the glow plug wiring in that harness is part of the main engine harness (all wrapped in one ), is it possible to run new wires outside of the loom yeah ,be a lot of work


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post #7 of 21 Old 12-24-2018, 09:41 AM Thread Starter
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Originally Posted by SCUFFY828 View Post
all the glow plug wiring in that harness is part of the main engine harness (all wrapped in one ), is it possible to run new wires outside of the loom yeah ,be a lot of work
Thanks for the info. So from the experiences guys information what would cause the one post/wire in the picture to get so hot it smokes/melts the plastic? Also looks like I'll be cutting into that part of the harness to see if it melted other wires.

if I do the AIH delete with the wire to prevent soft codes does it kind of rule out the AIH relay I accidently replaced with a glow plug relay? Not much info on AIH wiring so wanted to see how it could have caused the gpr to roast only one wire.

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post #8 of 21 Old 12-24-2018, 09:50 AM
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Quote:
Originally Posted by JustinOOO9 View Post
Thanks for the info. So from the experiences guys information what would cause the one post/wire in the picture to get so hot it smokes/melts the plastic? Also looks like I'll be cutting into that part of the harness to see if it melted other wires.

if I do the AIH delete with the wire to prevent soft codes does it kind of rule out the AIH relay I accidently replaced with a glow plug relay? Not much info on AIH wiring so wanted to see how it could have caused the gpr to roast only one wire.
the big supply wire going to the glow plug relay is handling a lot of load ,i see a lot of truck that come in shop with those wires melted and such , but still operating normal , they get extremely hot even when working properly , without running my own diag on this truck , just a couple things i've seen , glow plugs may be working but are working at a higher resistance than they should be , high resistance is high heat , the wire end that melted also is causing higher resistance ,so it smokes from that heat ,probably has nothing to do with intake heater which doesn't come on unless real cold anyway


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post #9 of 21 Old 12-24-2018, 09:55 AM Thread Starter
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Quote:
Originally Posted by SCUFFY828 View Post
the big supply wire going to the glow plug relay is handling a lot of load ,i see a lot of truck that come in shop with those wires melted and such , but still operating normal , they get extremely hot even when working properly , without running my own diag on this truck , just a couple things i've seen , glow plugs may be working but are working at a higher resistance than they should be , high resistance is high heat , the wire end that melted also is causing higher resistance ,so it smokes from that heat ,probably has nothing to do with intake heater which doesn't come on unless real cold anyway


Ok, in 2016 I replaced both sides : glow plugs, UVCH, valve cover harnesses with oem motorcraft, then 3 months ago I swapped my western plow relay in place of the aih relay on accident. now my gpr is smoking so do you feel this is a coincidence for my crank no start? I was planning on cutting/following then replacing the hot wire as far as I could in the main harness then replacing the GPR and trying again. I have a cps but I see rpms, wts light and have smoke coming out exchaust and rpms are jumping up when cranking.

-99 F250, 4X4, 6.0 trans cooler, 08 mirrors, 05 grill, AIS Intake, lvl kit, JW Vbody, cncfab hpop lines, WW2.

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post #10 of 21 Old 12-24-2018, 12:27 PM Thread Starter
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PS. Does anyone have a cheat sheet or what gauge fuseable links go to what wires on the glow plug relay? I found some pictures but they are on those sites that make you pay for access. Local ford dealer didn't have them either.


Also to everyone who posted up before and today Merry Christmas. Hope you all get to enjoy the holidays.

-99 F250, 4X4, 6.0 trans cooler, 08 mirrors, 05 grill, AIS Intake, lvl kit, JW Vbody, cncfab hpop lines, WW2.

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