Haynes manuals make it harder for people to try and troubleshoot electrical problems as they leave out important details and redraw them all weird.
Heres the ford version of the starting system, the connector numbers are really helpful for identifying where things are in the truck, for example...
I don’t have a build thread but I could start one, if someone wanted to help out with some graphic design or anything else I would definitely start a thread and it would be all open source for anyone to make.
I found the after market gauge clusters to be very lacking on anything extra, I don’t want to pay over a 1k for the same gauges as factory but more accurate so I started designing my own.
I’m not a graphics designer by any means so it’s fairly basic but I think it will do for what I need right...
Unfortunately the meter I have only reads down to 0.01 ohms so I can’t directly measure the Z resistor resistance but doing some calculations you can get fairly close. I’ve measured a few dozen zd9 glowplugs and they are all around 0.25ohms cold, take 8 of them in parallel and you get...
All you need to do is cut notches in the big Z resistor on the controller to increase its resistance and the controller will think it’s seeing a higher current draw then what the plugs are drawing. If you look at the Z resistor you will find a hole close to one of its ends, that’s how the...
94 is all prewired for cruise, you just need to get the cruise module and a cruise steering wheel and the brake pressure switch.
The cruise module can be from any truck, they all seem to work the same though there is a unique part number for each engine and probably small programming changes...
What year truck are we talking about here? 92.5-94 is a bolt in deal, 92.5 and lower used the vacuum cruise control which can easily be adapted to the newer electronic cruise.
Fusable links don’t have an exact ratting and the big thing to remember when gauging wire and fuse size is time, a fuse could do 300% it’s rated current for 30 seconds before blowing, wire is rated on how much it will warm up over time vs current. 4ga wire mite have a half voltage drop across it...
The TECA is bolted to the firewall and slides into the cab, on 87-91 trucks you removed it from the drivers side kick panel, on 92-97 trucks it sits in the same spot but comes out the engine bay. Your TECA relay is working fine as the transmission is shifting, if it didn’t work you would have...
Does the OD light flash? If you push the OD off switch does the light come on? Is the OD light dimly lit and doesn’t do anything?
At the fipl do you have 5 volts between the outer 2 wires? 0.75v is to low and you should have stacked shifts at that setting.
The TECA is on the drivers side...
Each plug draws around 30-50A when cold and depending on battery voltage, I’ve tested a lot of glowplugs for these trucks and the average resistance is 0.25ohm per plug. 8 plugs in parallel is 0.03ohm, battery drop with plugs on is about 10V, 10/0.03=330A this drops fast as the plugs heat up but...
Personally I would ditch that dinosaur of an alt and go with an internally regulated one, that thing uses expensive regulators, requires a relay to run and its non weather proof connector is going to give you issues at some point in the future.
exp.
Generally the under 8500# gets the smaller booster and over 8500# gets the bigger booster, you can put the bigger one on a truck that had the smaller one and get more brake pressure, good when towing a heavy load.
Over 8500#
Under 8500#
Edit: all idi trucks will be over 8500-9000# depending...
You don’t need to disconnect the starter lead with this switch, these are really designed to go in between the battery and the main feed to the cab, just disconnect the 6/4ga wire that goes from the battery to fender starter relay and hook it to one post of the switch, then get a short piece of...
I was in the same boat you are in a few years back, did a ton of research about the rsk and wanted to do it before the price became stupid high trying to order parts from the states, then hearing a few people started to get cracked frame horns and you have to lift it to use the kits available...
What year truck do you have?
Personally I would put factory ac in, it’s not hard and you can buy everything new for $300-$500, you will need the heater controls with ac from a donor truck and the under hood air box with ax also.
You will need to stay with the same engine for a donor as the...
Just FYI, it’s is somewhat common for the ignition switch itself to fall apart, it’s all pot metal and the crimp tabs can break off and the switch falls apart, just putting out the worse of the worse lol
Ya I just grabbed one from another truck, probably impossible to find a new one and if you did it would be the whole dash harness.
Just be careful when your prying the little locking clips back that you don’t over do it, the old plastic can break easy sometimes.
You will most likely have to swap the v-belt pulley from your old alt to the 3G alt as finding a 3G with 2 v-belt pulley isn’t as common as serpentine belt.
As for case size, you want the two hole version.
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