Engine/Transmission (1994 - 1998) Melted Grid Heater wires-help

[CThomsen]

Started truck tonight to go to a meeting and it started hard like batteries were weak. Drove 3 miles shut down for and hour. Started normally after meeting and drove home. Popped hood and found drivers side grid heater wire (rubber boot) completely melted and pass. side partially melted. Relays bad? any advice is appreciated. Also, is it safe to drive now or should I try to disconnect wires. Thanks

Just went out and did some checking. The relays under the drivers side battery each have 2 large rubber boots and 2 small rubber boots correct? If so, the small green wire going to one of the small boots is rubbed bare with wire exposed. If this is the problem, do I just need to fix this wire?

 

[JDLight]

One of mine melted, I found it had a loose connection. The nut that holds the wire to the grid heater was not tight and it caused the connection to over heat.

 

[Timebomb]

Mine did the same thing, As stated above my connection was loose

 

[J Shocik]

I had a loose connection on my truck too. Only mine was caused by the relays being corroded by the battery, breaking one of the wires at the relay. Couldn't tell by just looking. Found this out when replacing the relays. I was able to crimp another heavy duty end on the rotted end and it works to this day.

Just another thing to watch for...

 

[RDyson]

I have an 03. I had a grid heater meltdown about 2 months ago. One of the solenoids had stuck and melted the boots on both ends of the harness and blackened the grid heater and intake horn. I bought a new harness, grid heater and solenoid. When I changed everything out, I think all I needed was a new solenoid. I took the old one apart and the contacts were welded together. So I spent $300+ for a $25 solenoid, which is all I really needed.



Randy