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Old 08-16-2011, 01:39 AM   #1 (permalink)
Ravenwoods
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Fusible Links for Glow Plugs

A few weeks ago my 1997 2500 6.5 liter diesel began hard starting so I suspected a glow plug issue. Yesterday I replaced the four easy plugs on the driver's side. Truck definitely started right up after that. This evening I tackled the four harder glow plugs on the passenger's side and got them all changed.

Anyway, I found that the two middle wires were just hanging there and not even attached to the glow plugs. The front plug's wire is badly scorched and there is bare copper wire visible. The back plug's wire appears to still be fine. I've heard these wires are actually fusible links. The wires on the driver's side all clearly say fusible link on them and they are much fatter than the wires on the passenger's side. But the passenger side wires don't have anything that says fusible link. The two middle wires have disconnects so you can replace them easily. But the front wire just disappears with the the other two wires into one of those wire tube things and goes above the starter motor.

The two disconnected wires are easily replaced. But I'm puzzled about the front wire that has no disconnect and disappears with other wires above the starter motor. I had hoped there would be a disconnect there some place. I hope I don't have to remove the starter motor to fix this problem. I tried taking a few pictures but they didn't turn out well.
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Old 08-16-2011, 08:32 AM   #2 (permalink)
racer55
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There is a member here who makes a complete glow plug harness and sells them privately-not cheap but the quality is there.
Check your Private Messages.
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Old 08-16-2011, 08:59 AM   #3 (permalink)
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the middle wires with the disconnects are available from the dealer. they have the disconnects as they burn up around the turbo often and need to be replacable.
not sure of the wiring srtup on the 6.5, but on the older 6.2's, the GP wires were just lighter gauge so they would burn out easy on a short
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Old 08-16-2011, 05:59 PM   #4 (permalink)
Ravenwoods
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Originally Posted by Diaric View Post
the middle wires with the disconnects are available from the dealer. they have the disconnects as they burn up around the turbo often and need to be replacable.
not sure of the wiring srtup on the 6.5, but on the older 6.2's, the GP wires were just lighter gauge so they would burn out easy on a short
So I'll go to the dealer and get the two middle wires for now. But if I want to replace the front wire that is bare copper, do I just cut it somewhere and run a new wire that is a fusible link? Where do you hook up the wire?
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Old 08-16-2011, 06:27 PM   #5 (permalink)
racer55
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Here is a diagram for ya:
I am going to drive this thing off a cliff!!!!!
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Old 08-17-2011, 10:00 AM   #6 (permalink)
Ravenwoods
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Originally Posted by racer55 View Post
Wiring diagrams are like a foreign language to me. So if I want to fix that one front glow plug wire on the passenger side, does that mean I need to do all four glow plug wires on that side? Or can I just do that one plug?
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