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The glow plug relay on these is a common failure point. If you look on top of the engine there are two large relays located to the passenger side of and just back of the cover over the fuel filter. The one furthest back (also shorter) is the glow plug relay. There are two large and two small terminals. There should be battery voltage on the large terminal towards the passenger side all the time. If there isn't, there's a fuseable link under the passenger size battery that's probably open. If there's voltage there, put the voltmeter between the two large terminals and have someone turn on the key (but don't start the engine). With the key off, there should be battery voltage or something pretty close to it between the two large terminals. With the key on, the voltage between the terminals shouldn't exceed a few tenths of a volt. If the voltage drop across the relay is more than a few tenths of a volt, the relay is bad. They're relatively expensive from a dealer, as in $75 - $100, but a lot of auto parts places have generic ones that can be made to work. I just replaced mine, ended up costing $19 for a generic one. If replacing the relay doesn't solve the problem, you either have a wiring problem or bad glow plugs. In order to replace the glow plugs you have to remove the valve covers. The under valve cover harnesses are known to have problems also. They're a lot cheaper from an International truck dealer than from Ford. I still need to replace a couple glow plugs in mine, but just haven't had time yet. I just keep it plugged in when its cold if I think I'm going to need it. Keith
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