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Article No. 96-01-07	HARD START - 7.3 DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94
Publication Date: JANUARY 2, 1996

ISSUE:

The glow plug relay may melt and result in a no start/hard start condition.  This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay.

ACTION:

Increase the torque of the nuts on the glow plug relay and add a lockwasher.  Refer to the following Service Procedure for details.

NOTE:

THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES.

SERVICE PROCEDURE

CAUTION:

DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER.  BATTERY VOLTAGE IS PRESENT AT THE TERMINALS.

1. Disconnect the batteries.
2. Remove the glow plug relay plastic terminal cover.
3. Remove glow plug relay nuts.
4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts.

   CAUTION:

   ZINC PLATED LOCKWASHERS MUST BE USED.

5. Replace nuts and torque to 7.9 ±0.6 N-m (70 ±5 lb-in).

   CAUTION:

   DO NOT OVERTORQUE.  DAMAGE TO THE RELAY WILL RESULT.

6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs.  Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure.  Replace the cover.
7. Reconnect the batteries.

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

DEALER CODING

OASIS CODES:

203000, 203200, 601300, 602300, 603300