Engine/Transmission (1994 - 1998) 40amp engine run fuse blows

[HPagel]

Tuesday ... cold wet snow coming sideways ... ran into store ... come out to start truck ... . starter groans and blows 40 amp maxi fuse under hood ..... replace fuse, starter groans, blows fuse. I have been paying for road service for 12 years and never used it. Had the truck flat-bedded to the dealer. The dealer had it for 2 days and started it several times each day and never blew a fuse, everything checks fine. I pick it up Thursday night it starts and runs fine. (The dealer only charged for the fuse)

Friday afternoon, try to start, groans and blows fuse. I am pulling the starter out in the morning and bringing it to a local re-builder. HERE'S THE ? Do you think it is the starter? My concern is the starter is not the only thing on that circuit ... could it be something else. Any suggestions will be welcomed.

'94 2500 original starter over 157k

I think it's mad at me

 

[Missouri Mule]

HPagel,

What number is the fuse?

Fuse 3(40amp) covers ignition switch.

Fuse 2 (40 amp) covers engine starter relay. I check this realy out.

The fuse(2) supplies power to relay. The igniton switch sends power to the relay which energises it when ignition switch is in start mode.





After relay wire would split, one would go starter solenoid the other to hold up coil of fuel shut off solenoid.



Something is pulling alot of power or is shorting out,relay wires, connection, electrical component.

 

[Howard Durand]

Has the ignition switch wiring recall been taken care of on your truck?

They install a wiring harness and relay to re-route the blower motor circuit (30 amp. ) around the ignition switch.

If it hasn't, the switch can become overloaded and fail which could possibly be causing the problem.

 

[HPagel]

Bill, Thanks for your help. It is the #3 fuse. I checked all of my DIY wires that may have been on that circuit, can not find any shorts. Replaced fuse and started engine. Engine is running and fuse is blown ???????? I guess the fuel shut off is good and on another circuit. (it never had to crank to start, just fire right up) I am still looking for shorts ... . no luck so far and everything else seems to be working.

Howard, Thanks also. That is one recall I did not know about. Blower was not working. I pulled 30 amp under dash it's good but left it out. replaced 40 amp #3 and started engine several times without blowing #3. Did I get lucky or is the old girl playing tricks on me.

 

[Missouri Mule]

HPagel,

She's playing tricksOo.

What did the 30 amp fuse under dash go to?

Hard to beleive ( funny) that pulling a 30 amp fuse that probably has nothing to do with the 40 amp fuse would keep it from blowing.

 

[HPagel]

Bill, The 30amp was for the fan blower motor. After removing I started it 11 times ... . no problem. I am waiting till morning to start it cold. If it starts I will replace 30 amp and see what happens. I only have one spare 40 amp maxi left. #@$%!

I think the old girl is mad at me.

I tried the fan with the 40 amp blown and it did not work. replaced 40 and it worked. I think like Howard suggested it has something to do with ignition switch. Thanks again, I will keep you posted.

 

[HPagel]

Now I'm really confused. Cold started truck this morning three times ... . no problem. Drove twenty miles for more 40amp maxi fuses (I have depleated all local sources) Came home, shut off truck and restarted several times. Replaced 30amp blower motor fuse, restarted several times no problem. THIS IS DRIVING ME CRAZY! I will wait till it is cold tonight and try again.

 

[Missouri Mule]

HPagel,

The gremlin has to be in the ignition wiring more than likely in the wiring going from PDC to connector of ignition switch(bottom left side of steering column). You can check the connector/connections out with trouble light. You can check out ignition switch by putting light on several wire connections and jiggle key while in on position(definitely do this with the main power wire coming from pdc).

 

[HPagel]

M_M, Looks as if my head is under the dash again, first thing in the morning. Thanks, Hank

 

[Howard Durand]

I don't know if you can still get the blower wiring changed out under the recall but it would be a good idea to have it done.

The reason for the change is to take the load off of the ignition switch. The blower load is too much for the switch contacts and has caused them to get hot and short out.



In view of what has been happening, your ignition switch may already be damaged.

 

[HPagel]

It has been several days since the gremlin has disappeared. I just wanted to thank everyone for their suggestions. Something made it go away and I hope it stays away till my new truck comes in.