hawk-aggie
Member
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- Location
- College Station, Texas
I searched the forums, but.... forgive me for rehashing any previous post. Relatively new to the forum. Been lurking awhile, but now have an issue that has me stumped. I've gotten some ideas from some of the threads I've reviewed, but my knowledge has gaps. Below is my story - sorry for the length.
6.2 engine
Replaced fuel pump, fuel injector pump, fuel filter and separator, glow plugs, oil filter and oil, and transmission fluid. Had to pull the heads because of a blown gasket on one side and water intrusion to one of the cylinders on the other. While the heads were off, I seriously clean the grounding points. Lightly flex-honed all the cylinders. Reassembled everything. Installed new batteries. When all that was done, the thing cranked like a champ. Bled all the fuel lines, and it fired up! Progress. Took it for a 2 mile test drive. Ran well and didn't present any issues. Almost done and ready to be parked with the other M998s in the compound, but I'm getting ahead of myself.
The rear main seal sort of resealed itself for the most part, but the power steering pump had a small leak. Tightened up the hose clamps, wiped off the wet area underneath, and attempted to start it. It cranked well, the engine began to catch, but I let off the ignition switch a little soon. It died. Turned the ignition switch off, then back to run. Wait light came on for about a second, then went off AND the fuel gauge bottomed out as well - as it would if it lost power. Switched to start - nothing. Weird thing is I thought I could hear a slight crackling and thought I saw a whiff of smoke from the passenger side. (paranoia?) Turned the ignition switch off and those two alleged issues quit. I have yet to find any crispy wires, and I really don't want to do a "smoke" test. Thought the "burnt" smell came from the starter. Took it off and had it tested - all good in the starter world. Reinstalled starter. While I was up there around the starter, I removed the radio power cable at the lug connections on the outside of the battery box, and the connections appear clean with no corrosion. The wires at the end that radio cable were very dry and cracked, but there didn't appear to be any evidence of burning.
I decided to remove the KDS 2699 and replace it with another unit. (Unbeknownst to me, the truck has a yellow stripe glow plug controller and a green sticker smart box. Apparently, the last unit that had this one installed that combination and it worked for me until....). When I opened up the smart box, I found it got fried (see photo). Also, the component shown in the second photo was rattling around loose inside. Ok, that whole burnt thing would definitely be a problem, but what caused it?
I checked all the glow plugs. All were in the 1.2-1.5 ohm range. I installed a KDS-2695 yellow sticker smart box. Reconnected the batteries. Switched to "run" and nothing - no wait light, no cranking, not squat. I intend to remove the smart box and open it, but I haven't gotten back to it. I'd say there is a short somewhere, but right now I'm at a loss as to where to start. I HATE ELECTRICAL ISSUES!
I have not changed the glow plug controller, and I don't have that famous grounding harness installed.
Grill me or advise me - your choice. Any help or tips will be welcomed.
6.2 engine
Replaced fuel pump, fuel injector pump, fuel filter and separator, glow plugs, oil filter and oil, and transmission fluid. Had to pull the heads because of a blown gasket on one side and water intrusion to one of the cylinders on the other. While the heads were off, I seriously clean the grounding points. Lightly flex-honed all the cylinders. Reassembled everything. Installed new batteries. When all that was done, the thing cranked like a champ. Bled all the fuel lines, and it fired up! Progress. Took it for a 2 mile test drive. Ran well and didn't present any issues. Almost done and ready to be parked with the other M998s in the compound, but I'm getting ahead of myself.
The rear main seal sort of resealed itself for the most part, but the power steering pump had a small leak. Tightened up the hose clamps, wiped off the wet area underneath, and attempted to start it. It cranked well, the engine began to catch, but I let off the ignition switch a little soon. It died. Turned the ignition switch off, then back to run. Wait light came on for about a second, then went off AND the fuel gauge bottomed out as well - as it would if it lost power. Switched to start - nothing. Weird thing is I thought I could hear a slight crackling and thought I saw a whiff of smoke from the passenger side. (paranoia?) Turned the ignition switch off and those two alleged issues quit. I have yet to find any crispy wires, and I really don't want to do a "smoke" test. Thought the "burnt" smell came from the starter. Took it off and had it tested - all good in the starter world. Reinstalled starter. While I was up there around the starter, I removed the radio power cable at the lug connections on the outside of the battery box, and the connections appear clean with no corrosion. The wires at the end that radio cable were very dry and cracked, but there didn't appear to be any evidence of burning.
I decided to remove the KDS 2699 and replace it with another unit. (Unbeknownst to me, the truck has a yellow stripe glow plug controller and a green sticker smart box. Apparently, the last unit that had this one installed that combination and it worked for me until....). When I opened up the smart box, I found it got fried (see photo). Also, the component shown in the second photo was rattling around loose inside. Ok, that whole burnt thing would definitely be a problem, but what caused it?
I checked all the glow plugs. All were in the 1.2-1.5 ohm range. I installed a KDS-2695 yellow sticker smart box. Reconnected the batteries. Switched to "run" and nothing - no wait light, no cranking, not squat. I intend to remove the smart box and open it, but I haven't gotten back to it. I'd say there is a short somewhere, but right now I'm at a loss as to where to start. I HATE ELECTRICAL ISSUES!
I have not changed the glow plug controller, and I don't have that famous grounding harness installed.
Grill me or advise me - your choice. Any help or tips will be welcomed.
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