DogHead Relay Mod Backfire?

[usmcpatriot]

Thanks M1008driver for the help. I used the tractor relay that the mod called for that one worked for 3 turns of the key. So I replaced it with the ST553. It's six or half dozen of the other.
At the present moment I am jumping the starter relay with a switch....I found a wire I never saw before hanging loosely....A purple wire with a white stripe and a yellow wire together...tested that wire and its 10.25v Anyway thxs. I'll figure it out.

 

[Warthog]

Post a better picture of the "new" wires. Looking thru the wiring diagrams, I'm not seeing anything yet.

Need to see the connector.

 

[cpf240]

I think this was covered before, and determined to be the neutral safety switch: http://www.steelsoldiers.com/cucv/78192-mystery-wire.html

 

[Warthog]

I think this was covered before, and determined to be the neutral safety switch: http://www.steelsoldiers.com/cucv/78192-mystery-wire.html

I had forgotten all about that thread.

OP...What is the manufacture date of your truck?

 

[usmcpatriot]

Roger, doghead will check thread about the mystery wire, and here is info you wanted.
Thank you, really thanks alot.

 

[Warthog]

Yep it appears to the neutral safety switch wire that was used on the early versions of the truck. It needs to be attached to the neutral/backup lights switch on top of the steering column.

If it isn't attached, that will cause a not start situation.

 

[Warthog]

From reading the descriptions in the early posts and looking at the Civvy Wiring diagram that Doghead posted, this diagram "should" be what is happening with the "mystery wire"

I do not have an early truck and have not looked at that wiring, so YMMV

 

[usmcpatriot]

I'll be dropping the steering column this weekend to reattach the wire. Thanks for the help Warthog.

 

[M1008driver]

My understanding about the neutral safety switch is some vehicles will start without one and some will not. Mine starts with it removed. It also controls your backup lights, so you need it working.

I learned all this on this forum. That is why doghead strongly encourages us to keep the information of the same kind all in one thread and not several when we are asking help questions. It is a record for the next person to use when troubleshooting his vehicle.

Peace!

 

[Warthog]

My understanding about the neutral safety switch is some vehicles will start without one and some will not. Mine starts with it removed. It also controls your backup lights, so you need it working.

It is that some CUCV trucks HAVE the neutral switch wiring and most do not.

If it has the wiring then it has to be hooked up.

The backup lights share the same switch but are totally separate.

 

[pbrstreetgang]

Where should I look next if I am getting no voltage at my starter relay (doghead mod) with key on or off?

I just replaced glow plugs, glow plug relay, underdash relays from CUCV electric

Truck fired up but starter was sluggish almost like batteries were weak. Drove around for a couple of days and then yesterday, home at lunch, went to start and clack. Smoke came from starter underneath.

I dropped starter, replaced solenoid last night.

Now only clicks at underdash relay, no voltage there

Starter switch maybe?

 

[Warthog]

First check and loadtest your batteries. Never start troubleshooting your electrical system until you know for sure your batteries are good. Don't guess. Eveb new batteries can go bad.

At the relay under the dash, the large red wire should have 24v at all times. the small purple and white wire should have 12v only when the key is in the start position

If the red wire has no voltage, check the fusable link on the 24v Positive Terminal Block

 

[indy4x4fab]

Just reposting a few pictures.

 

[pbrstreetgang]

Ok will yank the batts tomorrow to have tested
Jumped red 24v to purple white on starter relay, and now when
I turn the key i get a click at the under dash relay and now
A click at the starter. New Solenoid will not turn starter over
I will check batts and post back here after

 

[M1008driver]

Always check your grounds too. Probably not your problem with the smoke from the starter area. 24 volt, right?

 

[pbrstreetgang]

Ok, took batteries to advanced for load test
Batteries registered good but,
Readings were 1017 cca but batteries are rated 750
Cca.

???? Overcharged??

I ran a jump wire from front battery to starter
All I got was sparks

Key turned starter relay clicks, starter clicks
But will not spin

 

[mistaken1]

Did you pull the inspection cover and check the starter gear and flex plate. Another member (edpdx) had an issue similar and his starter gear was wedged tight into his flexplate.

http://www.steelsoldiers.com/cucv/87641-no-start-started-again.html?highlight=start

 

[pbrstreetgang]

Yeah its not that, the starter is not bolted up
At present but rather sitting in there but
Wired up.

Any other suggestions to check

 

[Warthog]

The starter uses the mounting bolts for a ground. If it isn't connected you have to supply a ground wire.

 

[M1008driver]

I dropped starter, replaced solenoid last night.

24 volt, right? I don't know if you can just buy these at the auto parts store.

EDIT-

TM 9-2320-289-34
4-5. STARTER TESTING AND REPAIR