2002 7.3L Glow Plug Relay - Diesel Forum - TheDieselStop.com
'99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the '99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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post #1 of 31 (permalink) Old 12-30-2018, 01:10 PM Thread Starter
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2002 7.3L Glow Plug Relay

Decided to switch out my relay this morning. After swapping it out and trying to start it I saw smoke coming out. The power wire running from the GPR to the battery completely melted at the battery terminal?? I am sure that my wiring is correct, but have no idea why it melted? Any ideas on what might have caused this or how to fix it. The truck will turn over but will not start now... Looks like I am going to have to replace the entire wire from the battery to the GPR, or somehow splice it. TIA!
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post #2 of 31 (permalink) Old 12-30-2018, 02:11 PM
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Picture of what happen and how it is hooked up would help.


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post #3 of 31 (permalink) Old 12-30-2018, 02:48 PM Thread Starter
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Ok. Here are a few pics.
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post #4 of 31 (permalink) Old 12-30-2018, 03:50 PM
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What is the wire I have circled in red? It looks like a ground strap. The brown, yellow, and blue wires go on that terminal. Where does that other one lead to?
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I wonder if clouds ever look down on us and say, "Hey, look - that one is shaped like an idiot!"
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post #5 of 31 (permalink) Old 12-30-2018, 04:38 PM Thread Starter
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The terminal you have circled is opposite the "hot" terminal with the battery connector. It has the yellow and blue wires attached. These are the only 2 wires that can go on that terminal due the larger size. The other terminals are very small with small guage wire and small connectors. The "hot" terminal is larger and goes directly to the battery, which is melted now...
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post #6 of 31 (permalink) Old 12-30-2018, 04:43 PM
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What is the P/N and brand of your new GPR? Can you take a photo of the box?


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post #7 of 31 (permalink) Old 12-30-2018, 05:01 PM Thread Starter
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post #8 of 31 (permalink) Old 12-30-2018, 05:23 PM
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Quote:
Originally Posted by lj8215 View Post
The terminal you have circled is opposite the "hot" terminal with the battery connector. It has the yellow and blue wires attached. These are the only 2 wires that can go on that terminal due the larger size. The other terminals are very small with small guage wire and small connectors. The "hot" terminal is larger and goes directly to the battery, which is melted now...


I see the yellow and blue wires attached. There is also another wire attached which I took the time to circle in red. What is the wire circled in red? It looks like a ground strap.


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I wonder if clouds ever look down on us and say, "Hey, look - that one is shaped like an idiot!"
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post #9 of 31 (permalink) Old 12-30-2018, 05:31 PM Thread Starter
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Sorry.. Yes, it is grounded to the mounting bolt below it.
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post #10 of 31 (permalink) Old 12-30-2018, 05:33 PM
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Quote:
Originally Posted by lj8215 View Post
Sorry.. Yes, it is grounded to the mounting bolt below it.


In the picture, it really looks like that ground strap is attached to the terminal. That would explain what happened.


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I wonder if clouds ever look down on us and say, "Hey, look - that one is shaped like an idiot!"
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post #11 of 31 (permalink) Old 12-30-2018, 05:35 PM
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I don't know but could it be the new relay? I just replaced my GPR 2 weeks ago with a motorcraft from oreilly's and is working no problem.
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post #12 of 31 (permalink) Old 12-30-2018, 05:41 PM
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Quote:
Originally Posted by lj8215 View Post
Sorry.. Yes, it is grounded to the mounting bolt below it.
There should be nothing grounded to a mounting bolt off of the GPR.

You should have a hot wire from the battery, a key on hot wire, the wires to the glow plugs, and the signal wire from the PCM.

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post #13 of 31 (permalink) Old 12-30-2018, 05:45 PM Thread Starter
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Crap.. I will pull it back off and take a look.
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post #14 of 31 (permalink) Old 12-30-2018, 05:56 PM Thread Starter
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Ok. Good catch. The blue and yellow wire got pinched underneath the GPR when I installed the new one. A little electrical tape will fix those pretty easy. Any idea how to fix the power wire going to the battery??
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post #15 of 31 (permalink) Old 12-30-2018, 07:04 PM
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You might try the dealer but as old as the truck is you might have to have one made

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