Posted by Fritz Maurer on November 11, 2012 at 09:59:06 from (216.137.138.146):
In Reply to: Re: Ford 7.3 diesel posted by Mark-Ia on November 11, 2012 at 07:15:48:
During operation it's not unusual for the relays and the wiring to be warm; manifold heaters and glow plugs are heavy draw items. That fried relay was not the problem. If the relays are warm when the truck is not in service, something is energizing the relays. Easiest thing to do is remove the ground cables and install a low draw ammeter between the ground cable and negative post on either battery. Then pull the fuses out of the power distribution box while noting the ammeter reading as each one is pulled. Disconnect all owner added junk before pulling fuses. In many cases they just pick up a hot wire somewhere and it doesn't go through the PDB at all. When the PDB is completely empty of fuses, and there is still a draw, the harness is rubbed raw someplace. If there was any torch work done on the truck, check these areas for melted wires.
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