GP Relay Hot Supply Melted

[flareside_thun]

My GP's quit working and I noticed that the wires supplying power to my GP relay had melted in a certain spot. I don't know if it was a hack done by the PO or if it's the remnants of a fusible link. Has anyone else had this issue with theirs? What can be done as an "upgrade" for this?

 

['94IDITurbo7.3]

What can be done as an "upgrade" for this?

wire it up the correct way with the right fuses.

 

[gonecrazyi]

At the plastic plug? Pretty common spot. I just ran around that plug. Im surrounding didn't do itptoperly and should go back and remove the butt splices but it works for know.

 

[flareside_thun]

Nah, it's the two yellow wires......no plug. Some severely melted duck tape from the PO though....

 

[gonecrazyi]

Those yellow wires run through a plug that also contains all the wires for the top of the engine. The connector was probably melted in the past and that's how the po "FIXED" it lol.

Its a bad design dietectly from ford
.

 

[flareside_thun]

Ah, must have been because those wires were directly connected to each other no plug....

 

[Rot Box]

The 2 yellow wires should go from the relay/solenoid through the harness to a big plug on the passenger side fender and it usually melts right where the plug is.... Mine fried recently and I "fixed" everything the hard way

Take this with a grain of salt--I'm not an expert. If i could do it again I would unhook the two yellow wires from the solenoid and tape them up really well. Next take a big (4ga-2ga with crimped on ring terminals) wire directly from the battery and attach it where the yellow wires used to be on the solenoid. This should fix the problem for good.

 

[flareside_thun]

That's what I was thinkin about......cause like I said...the plug part of the whole thing has already been bypassed. I've notice that the serpentine style trucks used a single, heavier gauge cable instead of the two little ones...what the hell was Ford thinking????

 

[GOOSE]

This is a great time to relocate your controller. I mounted mine right behind the passenger side battery. A short piece of #4 wire off the solenoid seems much nicer. I then ran a #4 wire and #12 wires back to the back of the engine and soldered and shrink wrapped them to the harness. You can see the wire loom going back to the original location and tying into the engine harness. As stated, I just safed off the original yellow supply wires with shrink wrap and tape.

 

[franklin2]

Whatever you do, I would make some way to disconnect the wiring easily that goes over the valve cover to the engine. My two yellow wires melted also, but the smaller wires were ok. I crimped ring connectors to the yellow wires and then bolted them together with small bolts and nuts. I appreciated this when I went to change the valve cover gaskets, as I had to take all this wiring apart, along with the fuel filter stand, to gain clearance to get the valve cover off.

Nice when you have a mechanical project going on, that you are not side tracked messing with wiring and it just unplugs and moves out of your way. This would also be handy if the cylinder head or the whole engine needed pulling.

 

[flareside_thun]

I wish i had thought of relocating the relay before now. The new engine is already sitting in its engine bay.

 

[icanfixall]

My two yellow wires melted the engine wireing harness one day at startup. When I gifured out what all the smoke was from I went to a car audio speaker shop. Bought some heavy speaker wire and some terminal end. No more power issues going thru a way too tiny plug and wire harness....

 

[lotzagoodstuff]

This is a great time to relocate your controller. I mounted mine right behind the passenger side battery. A short piece of #4 wire off the solenoid seems much nicer. I then ran a #4 wire and #12 wires back to the back of the engine and soldered and shrink wrapped them to the harness. You can see the wire loom going back to the original location and tying into the engine harness. As stated, I just safed off the original yellow supply wires with shrink wrap and tape.

Nice job, looks great in its new easier to access home

 

[damac]

My truck was messed up big time when we got it, I went straight to the manual glowplug switch and left this wiring alone because it wasn't melted.

Kind of interesting when I look at other rigs in junkyards. Some had fine headlight switches, but this glowplug connector was melted. On mine something happened with the headlight switch and some other leads melted into others and caused all sorts of gremlins until recently I found a basic intact harness at pick and pull and I'm installing that tomorrow.

Does anybody think its worth fusing a new larger wire if using a manual push button for the glowplugs?

 

[franklin2]

Does anybody think its worth fusing a new larger wire if using a manual push button for the glowplugs?

The two yellow 10 gauge wires seem to work ok other than the plug problem. We have discussed this before, and you would have to use a huge fuse to handle the glowplug system. The fusible links are compact, tough, and work.