2002 7.3L Glow Plug Relay - Page 2 - 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 #16 of 31 (permalink) Old 12-30-2018, 07:10 PM Thread Starter
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You think I can disconnect the cable and pull it out of the sheath? I can call around to some batteries places tomorrow and see if they can make a cable with the lug on the end.
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post #17 of 31 (permalink) Old 12-30-2018, 07:11 PM Thread Starter
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BTW.. Are there any fuses or anything I need to check now?
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post #18 of 31 (permalink) Old 12-30-2018, 07:21 PM
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I doubt that you can pull it out of the sheath and can't help you much on the fuses.

However there should of been a fusable link in that cable to the battery to keep something like this from happening. I'm pretty sure that the OBS trucks have the fusable link in the cable that goes to the GPR.

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post #19 of 31 (permalink) Old 12-30-2018, 07:28 PM Thread Starter
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Thanks for the response. I have no idea what a fusible link is or how to find it?? I thought I might be able to just replace the cable, but of course that would probably be too easy.
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post #20 of 31 (permalink) Old 12-30-2018, 09:00 PM
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A fusible link is a smaller gauge wire that is spliced in-line that sacrifices itself in an overcurrent situation by burning up, working like a fuse.
A dealer should be able to supply fusible links.

On an '02, the glow plug wiring goes like this.

From the battery terminal connection there are two gray 12 gauge fusible links in parallel, then a black/orange 6 gauge wire to one of the large lugs on the GPR. That's the only thing on that lug. The other large lug on the GPR gets the brown and yellow wires to the glow plugs (both 10 gauge), and a 20 gauge fusible link (dark blue), connected to an 18 gauge white/light green wire that goes to the PCM. One of the smaller terminals gets an 18 gauge red wire from fuse 2.22 which is powered by the PCM power relay (hot with key on), and the other gets an 18 gauge violet/orange wire (also headed to the PCM to control the relay).

Like bugman said, there's no ground wire from any of the large terminals of the GPR. That would cause the fusible links in the power feed to burn up as soon as the key was turned on (or as soon as it was connected if on the power input terminal.

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Last edited by klhansen; 12-30-2018 at 09:03 PM.
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post #21 of 31 (permalink) Old 12-30-2018, 10:10 PM Thread Starter
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klhansen.. thanks for the information. So the fusible links (2) on the hot wire are closer to the terminal of the battery? That is what burned up? So essentially I should be able to splice in 2 fusible links to the existing cable and hook it back up to the battery then. How hard is this going to be? Seems like it shouldn't be that bad if I can find the fusbile links?
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post #22 of 31 (permalink) Old 12-30-2018, 10:52 PM Thread Starter
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So am I looking for something like this but in 12gauge?
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post #23 of 31 (permalink) Old 12-30-2018, 11:06 PM
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Yes, a pair of those in 12 gauge would work. Crimp the two of them into a ring terminal on the batter end and to the existing cable using an in-line crimp and some heat shrink tubing.

Everything should be available at a local parts store. I found 12 ga fusible link wire on napaonline.com. Just put two pieces in parallel.

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Last edited by klhansen; 12-30-2018 at 11:12 PM.
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post #24 of 31 (permalink) Old 12-30-2018, 11:11 PM
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You guys correct me if this is bad advice and I am not home for the next few weeks to check but I pulled my AIH some years back and seem to recall it had a nice heavy guage insulated wire with soldered ends running from the AIH to its relay.

If I was in a pinch, I think I would salvage this wire and see if its long enough to use for the GPR where this one melted.


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post #25 of 31 (permalink) Old 12-30-2018, 11:42 PM
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Quote:
Originally Posted by ArcticDriver View Post
You guys correct me if this is bad advice and I am not home for the next few weeks to check but I pulled my AIH some years back and seem to recall it had a nice heavy guage insulated wire with soldered ends running from the AIH to its relay.

If I was in a pinch, I think I would salvage this wire and see if its long enough to use for the GPR where this one melted.
Might be long enough for part of the wire that's burnt, but doesn't have fusible links built into it.

I believe the power feed wire to the GPR splices into the feed wire for the IAH relay AND for the alternator. I'm going to guess it's about 2 feet from the battery terminal to the GPR.

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post #26 of 31 (permalink) Old 01-01-2019, 08:22 AM Thread Starter
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klhansen and everyone else.. Thank you so much for the help. A simple fix and she fired right up. I should have changed out the GPR a long time ago. I was worried I was going to have to take it to the shop after looking at the burnt cables. Thanks again and Happy New Year!
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post #27 of 31 (permalink) Old 01-01-2019, 05:31 PM
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Quote:
Originally Posted by lj8215 View Post
klhansen and everyone else.. Thank you so much for the help. A simple fix and she fired right up. I should have changed out the GPR a long time ago. I was worried I was going to have to take it to the shop after looking at the burnt cables. Thanks again and Happy New Year!
What brand GPR did you install?

Some of them wear out fast.


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post #28 of 31 (permalink) Old 01-02-2019, 11:13 AM
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I think he said "Standard Ignition" brand from Oreilly's. Posted a link
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post #29 of 31 (permalink) Old 01-02-2019, 11:08 PM
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I think he said "Standard Ignition" brand from Oreilly's. Posted a link
Thanks.
In that case, he will probably get some experience changing it out.
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2002 F-250 4x4 CC SB 7.3 PSD w/4R100. 182,000 miles.
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SOLD:
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2000 F-250 4x4 SC SB 7.3 PSD w/4R100. 164,000 miles.
NOS Black CPS. Rebuilt Fuel bowl w/gold spring, 6.0 Cooler, Walker BTM, Stancor GPR, Michelin LTX M&S2.
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post #30 of 31 (permalink) Old 01-03-2019, 09:09 AM Thread Starter
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It was the standard from O'reilly. I didn't even know about the motorcraft until I started searching around.
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