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Some odd electrical problems


mtipton

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So, a bit of a backstory. The truck was taken completely apart and had been sitting for about 3 years. I’ve got it all back together now and am having a few electrical issues.

Blower motor doesn’t work

I have no dash illumination lights. Although the dash lights do turn on and get brighter with the heater controls🤷‍♂️

Wipers work, but very slowly

All exterior lights are working as they should

Radio works

Alternator is charging at around 14.4-14.5

I have changed both battery cables. Replaced engine to frame ground and engine to firewall ground. Also replaced every ground ring terminal in the engine bay

Any tips would be appreciated
 


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Uncle Gump

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It sure sounds like you still have a bad ground... probably a dash ground.
 

RobbieD

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^^^ X2 on a missing or bad ground.
 

mtipton

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Thanks guys, I suspected a bad ground myself that’s why I put new cables/ends on them. Went out today and checked every ground I could find. All are clean and the metal sanded down before installing.

The blower motor turns on now, but veeery slowly. Maybe I’m missing one somewhere. I count 2 on the passenger kick panel area. And 4 in the engine bay
 

Uncle Gump

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I have a bit earlier EVTM and it says there is one behind the IP to the left of the steering column.
 

mtipton

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Sorry, not sure if you mean the instrument cluster?
 

Uncle Gump

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No... behind the IP (Instrument Panel) to the left of the steering column. This is straight from a Gen1 EVTM. Your Gen 2 can't be much different.

Just get under there and have a good look. I also seem to remember a ground behind the driver kick panel... a-pillar area. But I believe that was on one of my many 94 Gen3 trucks.
 

mtipton

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No... behind the IP (Instrument Panel) to the left of the steering column. This is straight from a Gen1 EVTM. Your Gen 2 can't be much different.

Just get under there and have a good look. I also seem to remember a ground behind the driver kick panel... a-pillar area. But I believe that was on one of my many 94 Gen3 trucks.
Checked everywhere on the left side. No grounds anywhere. Even checked a spare dash I have in my garage from a 91.
 

mtipton

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No... behind the IP (Instrument Panel) to the left of the steering column. This is straight from a Gen1 EVTM. Your Gen 2 can't be much different.

Just get under there and have a good look. I also seem to remember a ground behind the driver kick panel... a-pillar area. But I believe that was on one of my many 94 Gen3 trucks.
So I did find one under some sound proofing on the driver kick panel. Cleaned it, but didn’t change anything.

I’ve tried 2 different dash’s with the same problem. My guess is it has to be in the engine bay somewhere
 

Uncle Gump

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You said one key thing that makes me believe dash ground. When you mess with the heater controls and the dash lights turn on.

They are coming ON with the heater controls because some power source is looking for ground and it finds it through the dash lights.

This is also one of the reasons that people doing their own repairs should spend a few dollars and buy the factory EVTM for their vehicle. It would let you see every ground point... what all is tied in with it and where on the vehicle it is located.
 

dvdswan

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I would verify all the interior grounds because that's where your issues are. Chances are a ground did NOT get attached and those circuits have to find the next closest ground.
 

mtipton

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I guess I’ll be pulling the dash again to take a better look. I know for a fact that the only grounds on the dash harness are on the passenger side.
 

dvdswan

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before pulling the dash, verify where the grounds are so when you do start pulling dash components look at the circuits to ensure no cables are chaffed, dry rotted, or only hanging on by a wire.
 

mtipton

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Okay, so I fixed the problem. And now everything is working perfectly.

Bit of a backstory. I originally had a 92 reg cab that got wrecked. Ended up buying a 91 ext cab and swapped my entire drivetrain and suspension to that truck. I guess somewhere along the line ford made a change in the harness that runs along the inside of the firewall. So I had 92 wiring harness’ everywhere except that firewall one. The main plug is missing a ground wire on the 91 harness that the 92 harness needs.

Whew. Thanks for all the input

Plug for reference
 

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Uncle Gump

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That was a head scratcher... way to stay with it and figure it out.
 


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