Hi, first thanks in advance. I've been reading the forums and decided today to replace all GPs and relay with new Motorcraft to fix a hard starting problem. I'm catching up all maintenance on the truck as a new owner just feel better knowing I've done it rather than guessing what's in there.
So 5 out of 8 GPs tested ok, but I replaced them all anyway and kept 5 for spares. Funny, the 5 good ones all ZD9, the 3 bad ones all Autolight. When I tested the relay it was delivering 11.5v to each of the GPs, and appeared to not switch off but the WTS light goes off after a few seconds. I'm ready to drop in the new relay and it is oriented just a bit differently so I want to double check before install. Please see photo - the posts are off by 90* clockwise from the one I removed. I noticed they both have a longer ridge on the top between a large and small post - is that the correct orientation for the wires? Thanks in advance for your help.
These relays are not polarity-sensitive, you can connect the wires 90 degrees off and you'll be just fine, as long as they don't short-out on each other.
It's a Motorcraft DY-861 (that's what it says on the box). I asked for the Motorcraft GP Relay from my parts store. Other than the terminals being 90* off they look exactly the same, although the part numbers stamped in the metal plate are different. I figure the old one is not Motorcraft. I did some research online to see if I could find others that are oriented this way, the only one I found was K-Mans on Ebay. My truck is 94 7.3L Turbo Diesel, and I removed the relay just a few inches to the right and forward of the turbo. Does it sound like I have the right thing? Could it be the one I removed was not a GP relay? I thought it was strange that it was delivering 11.5v (and not 9.6v) and didn't switch off, although it did click as expected up until a week or two ago. I'm just assuming it fried, and want to do the job right - definitely don't want to melt a $50 part! Thanks again, your help is appreciated!
Great, thanks for your help. Just so's I'm 100% clear - I can swap the big terminals and I can swap the little terminals?
You can swap between little and little, and beween big and big, but you can't put a small on a big and the other way around. Really, as long as you keep the small wires on the small studs, and the big wires on the big studs, you'll do just fine.
Quote:
Originally Posted by age
My truck is 94 7.3L Turbo Diesel, and I removed the relay just a few inches to the right and forward of the turbo. Does it sound like I have the right thing? Could it be the one I removed was not a GP relay?
You removed the correct part, Ford moved them to the valve cover for the turbocharged trucks only - if they kept it as the non-turbo models the turbo ends up right on top of it, and the heat that turbo makes is not good for wiring or electronics.
Busy week at work, I finally got back on the truck just now to finish up. It used to start really hard when cold and blow a lot of smoke at start. New glow plugs and relay, now no smoke and she fired right up. I checked my OP sender while at it and by re-seating the connector seemed to make a better connection and now I have a working OP gauge too. Beautiful!
Just wanted to say thanks to you guys for all the help.
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AJ Goldsmith
1994 F350 Dually
7.3 IDI Turbo Diesel
Pretty much stock
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