Iamnewatthis
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Problem this morning, need help./ Update! Truck runs ,Update in original post.
The batts. were dead.
Maybe due to new alt. belts i put on that weren't tight enough.
Maybe due to the main neg. batt. cable not being tight enough.
(didn't discover that till later)
The starter went out too, but that was just a coincidence that happened at the same time. I will run thru the sequence of events as best and short as i can for the benifit of others.
I made things worse when I was messing with the alternator by banging the wrench on the hot lead and the mounting bracket and fried a bunch of stuff.
I was in a black hole for awhile after i replaced all the fusible links and starter relay, as well as charged the batts. as the truck was still dead.
Adding to my confusion was having the batts. and starter tested at oriellys and them saying they were good. For whatever reason the bendix was kicking out on the tester but not in the truck. Of course i had no way of knowing that yet as i still had no power to the starter.
So i had good batts., supposedly a good starter, and a new starter relay. Still dead.
We all figured must be a bad wire.
I then actually started following the advice of those on here who were trying to help.
everything in bold is what guys on here told me to check first, everything else is parts i threw at it, either in desperation or for gp cause they were cheap and might as well.
Here's what i did;
1. cleaned all the contacts at the gang plug. They were covered in a tar like substance, it took 2 days but was worth it.
1.5 cleaned all the contacts on the fuse box side.
1.9 replaced all the fuses.
2. changed the ignition switch just for gp
3. changed the gen. 2 relay just for gp
3. Charged batts on a smart charger
I then had power to the starter.
I could here it spin, but it would not engage flywheel.
I then removed the cover plate, fly wheel had all its teeth put in park, chock blocked it, parking brake, had
friend turn key while i was under truck, could see starter spin but bendix not kick out.
I then removed starter again, had it rebuilt by a local guy who told me he had worked on one of these trucks before, and understood the 24 volt system.
Put new starter in.
Truck did not start at first and thank god as the starter relay stayed on and ran and ran the starter.
I just pulled the relay off.
I then purchased a borg warner starter relay instead of the AC40 thinking it would be better than the china mart from auto zone, wrong, it worked for 3 starts, then also malfunctioned.
I then did the "dog head relay conversion".
Truck started.
Then took back to old guy (meant as compliment) who rebuilt starter
and had alternators tested, and batts tested again. All good.
Also noticed volt meter indicated yellow even after driving it down there.
They told me to check all grounds.
On way home bought new nuts for all the batt. cables (they were stripped from taking on and off constantly and using the wrong wrench,13mm instead of 1/2 inch) and installed right there at the hard where store.
Voltage almost instantly went to green with new nut very tight on negative batt. post.
Truck good to go.
Here's what I learned;
As the guys on here said.
Check all your batt. connections.
Check your batts. are charged.
If its metal clean it.
Clean all the connections on the gang plug. (i had nothing happening till i did that, even after replacing components in the starting system)
Check/ replace fuses.
Look at the diagram and start isolating the problem. It can get pretty overwhelming just looking at all the wires in the truck.
Use the trouble shooting guides in the TM's, even if doesn't fix your problem it may and will help you learn how things work.
Use a 24 volt test light. And start testing for power in order of how things work. I was throwing parts at it at first.
Any connection you come across, clean it. Even if it's working now, as others told me, it's 25 years old.
Any rubber boots or covers you come across, replace them.
Disconnect the batts. before touching any thing electrical. That one i knew but was being lazy.
I want to thank everyone who helped me with this.
It was pretty stress full not knowing much about this truck or electrical stuff, and worrying that 5k i had into it went up in smoke, as well as sharing one working truck with my 2 kids, all of whom are trying to get to work or go to school. I could not have fixed this without your help.
Thank you very much.
As far as the smart asses on here who made jokes at my misfortune, KISS MY ASS.
I would just like to add that doing the recomended "must do's" in the FAQ
section is the way to go.
While i did replace the starter relay (AC40), and the GPR.
I did not clean any of the contacts, nor did i check or replace any fuses.
I would say if I bought another one of these, I would go thru and clean all the contacts at the gang plug,
replace fuses right off the bat, test the starter, alternators , and batts. before
I even drove it. Electricly speaking.
Simply checking the fluids, and changing the oil/filter aren't gonna get it.
Thanks again, enjoying my new truck again.
The batts. were dead.
Maybe due to new alt. belts i put on that weren't tight enough.
Maybe due to the main neg. batt. cable not being tight enough.
(didn't discover that till later)
The starter went out too, but that was just a coincidence that happened at the same time. I will run thru the sequence of events as best and short as i can for the benifit of others.
I made things worse when I was messing with the alternator by banging the wrench on the hot lead and the mounting bracket and fried a bunch of stuff.
I was in a black hole for awhile after i replaced all the fusible links and starter relay, as well as charged the batts. as the truck was still dead.
Adding to my confusion was having the batts. and starter tested at oriellys and them saying they were good. For whatever reason the bendix was kicking out on the tester but not in the truck. Of course i had no way of knowing that yet as i still had no power to the starter.
So i had good batts., supposedly a good starter, and a new starter relay. Still dead.
We all figured must be a bad wire.
I then actually started following the advice of those on here who were trying to help.
everything in bold is what guys on here told me to check first, everything else is parts i threw at it, either in desperation or for gp cause they were cheap and might as well.
Here's what i did;
1. cleaned all the contacts at the gang plug. They were covered in a tar like substance, it took 2 days but was worth it.
1.5 cleaned all the contacts on the fuse box side.
1.9 replaced all the fuses.
2. changed the ignition switch just for gp
3. changed the gen. 2 relay just for gp
3. Charged batts on a smart charger
I then had power to the starter.
I could here it spin, but it would not engage flywheel.
I then removed the cover plate, fly wheel had all its teeth put in park, chock blocked it, parking brake, had
friend turn key while i was under truck, could see starter spin but bendix not kick out.
I then removed starter again, had it rebuilt by a local guy who told me he had worked on one of these trucks before, and understood the 24 volt system.
Put new starter in.
Truck did not start at first and thank god as the starter relay stayed on and ran and ran the starter.
I just pulled the relay off.
I then purchased a borg warner starter relay instead of the AC40 thinking it would be better than the china mart from auto zone, wrong, it worked for 3 starts, then also malfunctioned.
I then did the "dog head relay conversion".
Truck started.
Then took back to old guy (meant as compliment) who rebuilt starter
and had alternators tested, and batts tested again. All good.
Also noticed volt meter indicated yellow even after driving it down there.
They told me to check all grounds.
On way home bought new nuts for all the batt. cables (they were stripped from taking on and off constantly and using the wrong wrench,13mm instead of 1/2 inch) and installed right there at the hard where store.
Voltage almost instantly went to green with new nut very tight on negative batt. post.
Truck good to go.
Here's what I learned;
As the guys on here said.
Check all your batt. connections.
Check your batts. are charged.
If its metal clean it.
Clean all the connections on the gang plug. (i had nothing happening till i did that, even after replacing components in the starting system)
Check/ replace fuses.
Look at the diagram and start isolating the problem. It can get pretty overwhelming just looking at all the wires in the truck.
Use the trouble shooting guides in the TM's, even if doesn't fix your problem it may and will help you learn how things work.
Use a 24 volt test light. And start testing for power in order of how things work. I was throwing parts at it at first.
Any connection you come across, clean it. Even if it's working now, as others told me, it's 25 years old.
Any rubber boots or covers you come across, replace them.
Disconnect the batts. before touching any thing electrical. That one i knew but was being lazy.
I want to thank everyone who helped me with this.
It was pretty stress full not knowing much about this truck or electrical stuff, and worrying that 5k i had into it went up in smoke, as well as sharing one working truck with my 2 kids, all of whom are trying to get to work or go to school. I could not have fixed this without your help.
Thank you very much.
As far as the smart asses on here who made jokes at my misfortune, KISS MY ASS.
I would just like to add that doing the recomended "must do's" in the FAQ
section is the way to go.
While i did replace the starter relay (AC40), and the GPR.
I did not clean any of the contacts, nor did i check or replace any fuses.
I would say if I bought another one of these, I would go thru and clean all the contacts at the gang plug,
replace fuses right off the bat, test the starter, alternators , and batts. before
I even drove it. Electricly speaking.
Simply checking the fluids, and changing the oil/filter aren't gonna get it.
Thanks again, enjoying my new truck again.
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