My truck has experienced intermittent stalling for the 11 months I've owned it. I tried various things but never messed with the PMD since as you all know it's a pain to get to. Last weekend I dug deep.


I removed the PMD, gave the transistor nuts a slight tweaking and mounted it to a heat sink in front of the rad to the brackets that hold the trans cooler (or power steering cooler, not sure which....on passenger side). I bypassed the OPS so the lift pump is running anytime the key is on. I'm aware of the controversial wisdom of this move but at this point I'm desperate to remove all unnecessary variables. I also took apart the ignition switch and cleaned the contacts. That was an ADVENTURE that some of you may understand. Lets just say that after finding myself with a handful of little springs and little "L" shaped levers it took me quite a while to figure out how to put it back together. After all that I started the truck and it stalled twice while idling in the first ten minutes. I then installed a used FSD that I acquired to my now easily accessible location (thank God) and it has run without a hitch since.


The relocation of the FSD is worth every bit of effort and then some just because it's so much easier to troubleshoot.


Thanks for the info guys, I've learned a ton here in the last year.

Alright Bob!


There's nothing like fixing the problem and in front of the radiator is a cool spot, although I've noticed rust on my mounting screws. Did you soder it together or buy an extension?


The tranny aux. cooler is on the passengerside.

I extended the harness myself and yes, I soldered the wires. I wanted to be SURE I had a good permanent connection. With it out front I'm no longer afraid to run my air conditioning, I was previously afraid of high under hood temps especially in slow traffic. I might even put that cool turbo power cover back on, although I like easy access to the filter.


I should also say that I didn't use that pad that is stock between the PMD and the IP. I used arctic silver and left the plastic covers off the transistors. I'm figuring that the plastic covers might hold some extra heat in the transistors. They don't touch the heat sink but are close enough to perhaps give up a little heat without the covers. An observation I made, I held the FSD in my hand (not yet on the heat sink) while the truck was idling and it felt to me like the transistors didn't get anywhere near as warm as the surrounding metal plate that touches the heat sink. Another interesting note, I felt a vert slight "tingle" when touching the transistor cases, which would be the collector. I don't know what's going on in that thing but I would think I shouldn't feel that with 12v. I didn't measure what voltage was there 'cause I was a little afraid of screwing something up.

Thought I would post a pic. One interesting note, the brackets for the trans cooler are perfectly spaced to accept the FSD between them. The two red dots are two of the nuts holding the FSD to the heat sink. I put vibra-tite on them that's why they are red.http://www.dieselplace.com/forum/uploads/Bobt250/2004-10-01_074703_IMG_0126.JPGhttp://www.dieselplace.com/forum/uploads/Bobt250/2004-10-01_074457_IMG_0125.JPG