Electrical fire

[Charlietoo]

1991 E350 conversion van, extended, lifted, raised roof, 129k

Used as a back up vehicle. Maybe 3-4 thousand miles a year. Lowes, nursery, hauling stuff. More lately as I get 22-25mpg which is better than my car.

Used it last night and the radio didn't work. Unusual but everything else was fine

Went to use it today but it wouldn't start. Cranked fast but it was like there was no spark (if it had spark).

The engine wait light would go out but the clicking didn't happen. I turned the key back and forth a few times and the clicking happened. Started up with a jump, high rev, funny sound and then settled into it's hum. Except something smelled funny and there was a white smoke coming from the pipe. I shut it down, popped the hood and black smoke came out. I looked under and could see yellow flames at the back of the engine. Ran in the house and grabbed the dry chem fire extinguiser and sprayed her down. Took the doghouse off and there was small flames so I sprayed more. It appears the glow plug relay or the wires shorted. The housing over the relay is melted. Two wires have the insullation gone. It still starts now but I am reluctant to drive it anywhere.

In the morning it will be cold enough to see if the clicking starts, right now it's 62 and it doesn't click.

Any thoughts what happened and why? I figure I need to replace the GPR and the plastic cover. Not sure where to get the cover or what it's called. Does anyone have a site with instructions to replace the relay? Stick with the Motorcraft or Stancor?

Would appreciate any feedback. I'm not a wrench, just enjoy diesels. Should I replace the easily accessible glow plugs or leave that to a tech.

Thanks

Charlie
Chambersburg, PA

[Charlietoo]

All fixed.

Called International and they had the glow plug controller in stock. Took the old one off and it was a job as it was a mess. Spent a lot of time vacuuming halo, being careful not to break any wires as I wasn't sure what belong to the harness and what was the controllers. Brought it with me to be sure the new piece was the same. Only about 15 minutes to put the new one on. No plastic housing so I tie wrapped those two cables up and away from the relay. They got a little melted but whateve they are, everything is working. Started right up, wait engine light went out and the clicking began. I'm happy.

Now, for the technical stuff.

On the relay is a white wire with a warning sticker that nothing else is to attach to it. That wire seemed to have gotten the hottest as it was totally fried. The other red wire coming out of the controller was also fried and the end was in ruins. On the top of the relay is about a 10 gauge heavy wire that I assume is one side of the hot, the nut was only finger tight. I had had glow plug work done at the dealer last year and suspect it had not been properly tightened. Not sure if one loose wire could cause that much trouble, but for what it's worth, that is my guess.

The only thing I'm missing is the plastic housing. International said it must be a Ford after market part as they do not make it. I'm guessing it is to keep debris off the relay. If anyone has a part number for that, I would appreciate it.

Cost from International was $128

There are three on eBay for $100. After shipping and waiting I couldn't see taking a chance that it was not the right part in the hopes of saving $15. I've done that before.

Anyone else contemplating it, just drop a line if you need a hand. Also, I DID undo both batteries first.

Charlie

[Mr_Roboto]

You're talking about the "Do not jump here" cover. It's there to keep tools etc from being dropped onto the LIVE electrical connections. There's enough current there to cause serious damage.

International uses a different glow plug system, that's why they don't have the cover.

If Ford doesn't carry the cover, make a cover out of heavy rubber to keep the connections covered.