1993 7.3 IDI, problems please help!

[nightwalkr]

I have a 1993 7.3 IDI, 5 speed crewcab longbed, 4x4, single rear wheel. The truck has 382,000 miles on it, I purchased it from the original owner who bought it brand new here in PA in 1993. I did a few things to it to get it running, I put new bosch glow plugs in and put new ends on the harness, batteries, starter, tires. It really didnt cost but $600 to get it running. It runs good for the most part. However recently I am having a few problems and there is no mechanic in this area who can tell me what the problems are. The first problem is the glow plug regulator is not working anymore or works when it wants to, I have replaced the whole thing with a used one but it didnt work, I replaced the solenoid and that helped but it is still not functioning properly, I have thought about bypassing and running a push button to regulate them manually but I am not sure how to wire it as I have no diagram.
Problem 2 my engine is starting to miss a bit and consumes a lot of fuel, it runs good under load but when the rpms are under 2k it hesitates and the throttle response isnt there. Maybe needs injectors rebuilt or seals? or maybe injector pump? It is all stock equipment none of it is reman I have all service records. The only mods I did was a straight pipe 4" exhaust (no performance traping 90 degree elbows only 45's) and a highflow air filter. These helped increase performance a decent amount. Problem 3 my brakes became hard and will no longer stop the truck properly, I thought bad booster, I replaced it this helped some but not a lot, so I am thinking vaccum pump? or maybe brakes need bled? The front brakes are new and the rear are also new. My last problem is my headlights only work when they want to, they flicker on and off low and high beam both. Is it the turn signal switch? or the light switch it self? The only way to keep them on is if I hold the highbeam flasher back the whole way while I am driving which is a chore with a 5 speed so I try not to drive at night. Thats what I got any help would be greatly appreciated as this is my daily driver. PLEASE HELP DIESEL GURUS!

 

[Compu Doc]

By the mileage it probably could use a new set of injectors and a new injection pump.

As for the glow plugs you could do a push button or replace the glow plug relay. They can be bought for not much money.

http://www.napaonline.com/Search/Detail.aspx?A=ECHGPC104_0307150721&An=599001+101993+50028+2028036

Check your vacuum pump and pull the hose at the booster to see if your getting a good amount vacuum.

Also welcome to the board and as luck would have it the annual IDI rally is being held in PA July 4th week 2011

http://www.oilburners.net/forums/showthread.php?t=42084

 

[dyoung14]

You need to get those bosch glow plugs out, before they burn out and swell in the heads, put some motorcrafts in it, and i bet your controller will function properly

 

[icanfixall]

Find the engine main wireing harnes disconnect plug. See if the two yellow wires are melting the plug. these are the wires that feed power to the controller and they are too small. Bypass the plug and run a single 6 gauge wire from a speaker shop. Use a heavy solder on lug and you will be fine... Usually this plug melts because it gets so much corrosion in it. that creates a much higher amp draw and lots-o-heat...

 

[nightwalkr]

You need to get those bosch glow plugs out, before they burn out and swell in the heads, put some motorcrafts in it, and i bet your controller will function properly

I dont think the plugs are the problem, the original owner had to put at least 2 sets of motorcrafts in per year, which is crazy, I called in to a friend who works at the Ford garage and they told me that the motorcraft plugs don't work very well in that engine and to use the bosch ones for longevity and not to use champions, or autolites because they swell bad. But I check the plugs routinley primarily #1 and #8 cyl. because I was told if they swell they usually start in one of those 2 cylinders. The glow plugs arent but 10 months old and aside from the standard bluish color look pretty good.

 

[icanfixall]

Motorcraft Beru plugs are the only type that will function properly in these motors. Others fit and work for a while but... they wont last. I can't say why the owner states the need for two sets of berus per year. That makes no sence at all. The very worst plugs in these motors are autolites and champions. There is history that backs up this statement. Some members have had to remove the heads because of plug tips breaking off in the heads. Others have plugs that swell up so bad the heads come off to remove them... This never happens with a beru plug. These are the facts based on experiance here...

 

[itsacrazyasian]

Motorcraft Beru plugs are the only type that will function properly in these motors. Others fit and work for a while but... they wont last. I can't say why the owner states the need for two sets of berus per year. That makes no sence at all. The very worst plugs in these motors are autolites and champions. There is history that backs up this statement. Some members have had to remove the heads because of plug tips breaking off in the heads. Others have plugs that swell up so bad the heads come off to remove them... This never happens with a beru plug. These are the facts based on experiance here...

Anything can happen, even with BERU plugs. They are just far less likely. Ask me how i know this, but that was back when i was still on TDS with my 91.

Motorcraft/BERU on a manual relay FTW. Light them up 10 seconds and away i go.

 

[nightwalkr]

Maybe they will work better, but as I am on a tight budget and this is my daily driver where do I get motorcraft plugs for this truck? Ford dealer here no longer stocks them and even if they did the last price was for $140 for 8.
any ideas?

 

[icanfixall]

Over the years since I bought my rig way back in 94 I knew nothing about glow plugs. In around 98 I had oil in the coolant so... the oil cooler o-rings were replaced... So was the injection pump and injectors. The return line kit along with the plugs were also replaced. After about 7 years I felt I had a plug problem... Wait to start lite burned foer about 2 seconds. So I removed all the plugs. Found the back cylinders on both heads had a champion and an autolite... The rest were beru... I paid for all the plugs to be changed... too late now... The champ and autolites had the tips burned off.... I have been running beru ever since. In 2006 I removed that motor and installed what I'm running now. Those back cylinders had some beat up pistons from the tips smashing around in there. I never have modified the glow system. Always run it just like it was designed to. The only issues I ever have had was the corrosion at the main wire harness shorting out and burning the harness plug and thats it. The berus run great. When I do a compression test I usually replace the plugs just because I have them out anyway. Never see a problem with them. Seems no matter how many miles I put on them they just continue to work. I'm not hard nor easy on my rig but I understand these are work engines made to earn a living off of. When autozone was selling out all their stock of beru ZD9 plugs I bought 8 or 9 sets for $2.99 each plug.... It was the deal of a lifetime. I have spares that I will use till they are gone. Plenty of members here also got lots of them thru the same sale. To make a statement that things can happen is true but vauge at best. So many members here have proven the worth of the beru glow plugs I just can't understand why some wont believe it. Facts speak more than the statement... I heard this about that"... Just ask around here. those that know wont disagree but we can agree to disagree with some of the newer posting too. I'm someone that enjoys learning more about these engines all the time. Some feel that I know more than all the others put together. Nope... I'm still finding out things I didn't know before... Take this to heart... You will not find a better glow plug than the motorcraft beru ZD9 for the solid state contorller systems.... That you can take to the bank....

 

[alienturtle]

I dont think the plugs are the problem, the original owner had to put at least 2 sets of motorcrafts in per year, which is crazy, I called in to a friend who works at the Ford garage and they told me that the motorcraft plugs don't work very well in that engine and to use the bosch ones for longevity and not to use champions, or autolites because they swell bad. But I check the plugs routinley primarily #1 and #8 cyl. because I was told if they swell they usually start in one of those 2 cylinders. The glow plugs arent but 10 months old and aside from the standard bluish color look pretty good.

I dont know how many posts i have seen on here where the autolite or champ glowplugs go pop. Everyone replaced with the ZD9 and wont look back. Thats after having a time getting them out. I had glow plug issues before i did my conversion and after doing everything that icanfixall has described she didnt care what temp it was. push the start button and off i went.

they are all over ebay

http://cgi.ebay.com/ebaymotors/FORD...ptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

 

[Cincinnati Guy]

Here is where a lot of us on here buy our plugs from, no need to pay more and get the same product.

I also stand by saying Beru/Motorcraft ONLY!

http://www.dieselfiltersonline.com/Zd9-Ford-7-3-Liter-Diesel-Motorcraft-Glow-Plug-Zd9.aspx

 

[nightwalkr]

I am still new to this engine and truck I have always drove Dodge but when my Dodge trucks pinion bearings went out I had to leave it sit and run this F350 till I get it up and running. I am not knocking anyones ideas just the opposite I am taking them all in meshing them together and trying to see what works, there are things I have been told that may be true or not but to me they sound logical and make sense. I really appreciate all those who are trying to help so far I have made great progress, at the moment I am trying to get a headlight problem fixed and cant seem to get anything to work. I have no headlights at all I have replaced the headlight pull-out switch and the turnsignal/highbeam dimmer switch but still problems, I even checked common problem areas such as wiring, and plug ends to no avail. When I turn my headlights on no lights at all high beam or low, and my dash indicator is stuck on highbeam reguardless of switch position, checked all the fuses and connections and nothing seems to be wrong, is there a switch I am missing? or a relay? I have a meter and I am going to start at the front and work my way to the switch and hopefully come up with at solution any help would be much appreciated. If I dont get all these "bugs" fixed soon I may have to retire "Mighty ******"(my trucks name)

 

[Nick_Rego]

Find the engine main wireing harnes disconnect plug. See if the two yellow wires are melting the plug. these are the wires that feed power to the controller and they are too small. Bypass the plug and run a single 6 gauge wire from a speaker shop. Use a heavy solder on lug and you will be fine... Usually this plug melts because it gets so much corrosion in it. that creates a much higher amp draw and lots-o-heat...

mine has done this recently im probably going to get the new wire today and I was thinking instead of running these off the hot side of my starter relay with numerous other things could I just run the new 6 guage wire from the driver aide positive battery over to my hot side glowplug relay? I have a first gen banks turbo so the glow plig relay is mounted to the fire wall on the driverside kinda above where the hump for the trans begins to transition. Also could i just use an actual battery cable for this? obviously the smaller guage probably is a 6.

 

[Nick_Rego]

im sorry it would be a starter cable and they are typically 4 guage. would something like that work?

 

[quickster]

This is a 10 year old thread.