86 5.0 Fox Body No Crank Issue (fusible Link/clutch Safety Switch)

Use the thinner one. The trigger wire to the solenoid/ relay doesn't need that thick. I'm always overly cautious on anything electrical. Put a fuse inline and 14-16 guage will be fine. Remember the relay on your fender absorbs the current to starter. You only use the starter for 1-3 seconds. Keep us posted if it fixes your problem.


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Use 16-18 gauge wire and use a 5 amp fuse. Ford used 18 gauge and they know a lot more about what is needed than anyone here on Stangnet
The 12 gauge is way overkill, wire size is determined by the amount o current it carries. A lager wire will work, but it is harder to bend and route.

Do not over fuse any wire!!!
 
Use 16-18 gauge wire and use a 5 amp fuse. Ford used 18 gauge and they know a lot more about what is needed than anyone here on Stangnet
The 12 gauge is way overkill, wire size is determined by the amount o current it carries. A lager wire will work, but it is harder to bend and route.

Do not over fuse any wire!!!

I thought 12 gauge seamed big, the wire running to the solenoid is only 18 gauge I believe. Anyways, I got out there in the pizzing rain and ran a new wire in like 5 minutes and she fired right up! Still going to check the switch when I get under there but in the mean time at least I'm mobile, thanks everyone for the help and advice!

Unfortunately, she now has a whole new issue, the car is driving rough and revving on its own, when I engage the clutch or put her in neutral it revs as high as 2000 rpm. If I shut it off and restart it, the revving is gone and she idles normal until it randomly starts up again, so thinking tps or something electronic. Any thoughts guys? I don't even wanna drive her like this, at least I traded a project for a project but dam lol.
 
Unfortunately, she now has a whole new issue, the car is driving rough and revving on its own, when I engage the clutch or put her in neutral it revs as high as 2000 rpm. If I shut it off and restart it, the revving is gone and she idles normal until it randomly starts up again, so thinking tps or something electronic. Any thoughts guys? I don't even wanna drive her like this, at least I traded a project for a project but dam lol.

Possible TPS problem. Dump the codes to confirm and watch for codes 23, 53 or 63. I have seen it do the same thing and not set a TPS code.

The tip off is that everything is normal when you shut the ignition switch off. That causes the computer to reset the TPS signal zero starting point to whatever the TPS may be putting out for a voltage reading.


Dump codes sticky

Look at the top of the 5.0 Tech forum where the sticky threads are posted. One of them is how to dump the computer codes. Codes may be present even if the CEL (Check Engine Light) isn’t on. You don’t need a code reader or scanner – all you need is a paper clip, or if your lady friend has a hair pin, that will do the job.
I highly suggest that you read it and follow the instructions to dump the codes. http://www.stangnet.com/mustang-forums/threads/how-to-pull-codes-from-eec4.889006/
 
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Possible TPS problem. Dump the codes to confirm and watch for codes 23, 53 or 63. I have seen it do the same thing and not set a TPS code.

The tip off is that everything is normal when you shut the ignition switch off. That causes the computer to reset the TPS signal zero starting point to whatever the TPS may be putting out for a voltage reading.


Dump codes sticky

Look at the top of the 5.0 Tech forum where the sticky threads are posted. One of them is how to dump the computer codes. Codes may be present even if the CEL (Check Engine Light) isn’t on. You don’t need a code reader or scanner – all you need is a paper clip, or if your lady friend has a hair pin, that will do the job.
I highly suggest that you read it and follow the instructions to dump the codes. http://www.stangnet.com/mustang-forums/threads/how-to-pull-codes-from-eec4.889006/

Happy Friday Jrichker! That seams simple enough but the diagram is sort of confusing, I see the one clip but what's the gray box it also shows? I was thinking the same thing with the reset when I turn it off, that's why I tried it. If it's likely the TPS, is there a test I can do with my multimeter to test just the TPS and not need to dump codes? Thanks for all to the advice, it's been very helpful!
 
Hey guys, new update;

I have a fuel line leak, same issue as before with my lack of wrenching area and jack to get under the car. Not sure if one thing after another is failing or would a fuel leak would cause the car to rev up to 2000 rpm on its own? Pretty sure it's just yet another problem simultaneously happening. Any input is as always, much appreciated!
 
Happy Friday Jrichker! That seams simple enough but the diagram is sort of confusing, I see the one clip but what's the gray box it also shows? I was thinking the same thing with the reset when I turn it off, that's why I tried it. If it's likely the TPS, is there a test I can do with my multimeter to test just the TPS and not need to dump codes? Thanks for all to the advice, it's been very helpful!
Since I am not standing by at your elbow watching you, I don't have a way to make it any clearer.

There are some tests you can do for the TPS, but they don't always find the problem that you are having.

TPS Troubleshooting and testing

Revised 2 July 2014 to reflect changes in resistance values for testing of TPS wiring.

Setting the TPS: you'll need a good Digital Voltmeter (DVM) to do the job. Set the TPS voltage at .5- 1.1 range. Because of the variables involved with the tolerances of both computer and DVM, I would shoot for somewhere between .6 and 1.0 volts. Unless you have a Fluke or other high grade DVM, the second digit past the decimal point on cheap DVM’s is probably fantasy. Since the computer zeros out the TPS voltage every time it powers up, playing with the settings isn't an effective aid to performance or drivability. The main purpose of checking the TPS is to make sure it isn't way out of range and causing problems.


Wire colors & functions:
Orange/white = 5 volt VREF from the computer
Dark Green/lt green = TPS output to computer
Black/white = Signal ground from computer

TPS troubleshooting steps:
1.) Use the Orange/white & Black white wires to verify the TPS has the correct 5 volts source from the computer.
2.) Use the Dark Green/lt green & Black/white wires to set the TPS base voltage. Try this... All you need is less than 1.0 volt at idle and more than 4.25 at Wide Open Throttle (WOT). You'll need a voltmeter with a 1 or 3 volt low scale to do the job.

The Orange/White wire is the VREF 5 volts from the computer. You use the Dark Green/Lt green wire (TPS signal) and the Black/White wire (TPS ground) to set the TPS. Use a pair of safety pins to probe the TPS connector from the rear of the connector. You may find it a little difficult to make a good connection, but keep trying. Put the safety pins in the Dark Green/Lt green wire and Black/White wire. Make sure the ignition switch is in the Run position but the engine isn't running. Set the voltmeter on the 2 volt range if it doesn’t auto range.

Here’s a TPS tip I got from NoGo50

When you installed the sensor make sure you place it on the peg right and then tighten it down properly. Loosen the back screw a tiny bit so the sensor can pivot and loosen the front screw enough so you can move it just a little in very small increments. I wouldn’t try to adjust it using marks.

(copied from MustangMax, Glendale AZ)

A.) Always adjust the TPS and Idle with the engine at operating temp. Dive it around for a bit if you can and get it nice and warm.

B.) When you probe the leads of the TPS, do not use an engine ground, put the ground probe into the lead of the TPS. You should be connecting both meter probes to the TPS and not one to the TPS and the other to ground.

C.) Always reset the computer whenever you adjust the TPS or clean/change any sensors. I just pull the battery lead for 10 minutes.

D.) The key is to adjust the TPS voltage and reset the computer whenever the idle screw is changed.

The TPS is a variable resistor, must like the volume control knob on a cheap radio. We have all heard them crackle and pop when the volume is adjusted. The TPS sensor has the same problem: wear on the resistor element makes places that create electrical noise. This electrical noise confuses the computer, because it expects to see a smooth increase or decrease as the throttle is opened or closed.

TPS testing: most of the time a failed TPS will set code 23 or 63, but not always. Use either an analog meter or a DVM with an analog bar graph and connect the leads as instructed above. Turn the ignition switch to the Run position, but do not start the engine. Note the voltage with the throttle closed. Slowly open the throttle and watch the voltage increase smoothly, slowly close the throttle and watch the voltage decrease smoothly. If the voltage jumps around and isn’t smooth, the TPS has some worn places in the resistor element. When the throttle is closed, make sure that the voltage is the same as what it was when you started. If it varies more than 10%, the TPS is suspect of being worn in the idle range of its travel.

TPS will not go below 1 volt

Note: Make all resistance checks with the ignition switch in the OFF position. Failure to do so will result in incorrect results and may possibly damage the meter.

Engine mounted sensor circuit: Check the resistance between the black/white wire on the TPS and battery ground. It should be less than 1 ohm. Higher resistance than 1 ohm indicates a problem with the 10 pin connector, computer or the splice inside the main harness where the wire from the 10 pin connectors joins the rest of the black/white wire.

attachment.php


See the graphic for the location of the 10 pin connectors:
Diagram courtesy of Tmoss & Stang&2birds

TPS_IAB_Pic.jpg


See the graphic for the 10 pin connector circuit layout.
salt-pepper-10-pin-connectors-65-jpg.68512


Unplug the white 10 pin connector to do some resistance testing. It is good time to clean the connector pins and examine the connector for corrosion, broken wire or other damage. See http://oldfuelinjection.com/?p=85 for help in this department.

If the resistance on the TPS Black/White wire and pin 1 of the white engine fuel injector harness 10 pin connector, is more than 1.0 ohm, you have bad connection or broken wiring. Repeat the test using the pin 1 of the white body side 10 pin connector and battery ground. You should have less that 1 ohm. More than that is a damaged signal ground inside the computer or bad connections or wiring.[/b]
 
Possible TPS problem. Dump the codes to confirm and watch for codes 23, 53 or 63. I have seen it do the same thing and not set a TPS code.

The tip off is that everything is normal when you shut the ignition switch off. That causes the computer to reset the TPS signal zero starting point to whatever the TPS may be putting out for a voltage reading.


Dump codes sticky

Look at the top of the 5.0 Tech forum where the sticky threads are posted. One of them is how to dump the computer codes. Codes may be present even if the CEL (Check Engine Light) isn’t on. You don’t need a code reader or scanner – all you need is a paper clip, or if your lady friend has a hair pin, that will do the job.
I highly suggest that you read it and follow the instructions to dump the codes. http://www.stangnet.com/mustang-forums/threads/how-to-pull-codes-from-eec4.889006/

Hey guys, Jrichker!

Been a hectic few weeks with storms, trying to launch a business and moving. Finally moved and have my very first garage! I did have to clean rat :poo: and buncha nasty stuff for like a day but well worth it! Got the rustang in there and finally got a test lamp (it was confusing with the dmm, spikes were inconsistent) and dumped my codes which are as follows:

KOEO: 31, 32, 33, 35, 63, 85.

KOER: 21, 94, 44, 31.

So should I just replace my EGR valve or try cleaning it first?
And should I replace my tps? Has been showing symptoms.
Actually drove better when I move it to the new place and I even took it out a couple times with much less acting up but still inconsistent idle, dies when first started after running for about 10 seconds for the first time of the day than its fine. I loved dumping the codes, so cool they were doing that back in 86, my cars talking to me!!

Cheers, Dylan.
 
Hey guys, Jrichker!

Been a hectic few weeks with storms, trying to launch a business and moving. Finally moved and have my very first garage! I did have to clean rat **** and buncha nasty stuff for like a day but well worth it! Got the rustang in there and finally got a test lamp (it was confusing with the dmm, spikes were inconsistent) and dumped my codes which are as follows:

KOEO: 31, 32, 33, 35, 63, 85.

KOER: 21, 94, 44, 31.

So should I just replace my EGR valve or try cleaning it first?
And should I replace my tps? Has been showing symptoms.
Actually drove better when I move it to the new place and I even took it out a couple times with much less acting up but still inconsistent idle, dies when first started after running for about 10 seconds for the first time of the day than its fine. I loved dumping the codes, so cool they were doing that back in 86, my cars talking to me!!

Cheers, Dylan.


Do not replace the TPS until you test it. Takes 3 minutes. Below is a link to LMR, which shows how to install and test the TPS. You can go one step further and after setting it. Actuate the throttle by hand and or have some press the pedal and watch the voltage increase to ensure there isn't a dead spot.

https://lmr.com/item/BBK-1684/1986-93-Mustang-50L-Bbk-Throttle-Position-Sensor-Tps-Sensor

The codes you are getting are for EGR stuff, this can be due to a vacuum leak as well. Check that first and report back before replacing stuff. Also do you have catalytic converters (might of missed this earlier in a post)?
 
Do not replace the TPS until you test it. Takes 3 minutes. Below is a link to LMR, which shows how to install and test the TPS. You can go one step further and after setting it. Actuate the throttle by hand and or have some press the pedal and watch the voltage increase to ensure there isn't a dead spot.

https://lmr.com/item/BBK-1684/1986-93-Mustang-50L-Bbk-Throttle-Position-Sensor-Tps-Sensor

The codes you are getting are for EGR stuff, this can be due to a vacuum leak as well. Check that first and report back before replacing stuff. Also do you have catalytic converters (might of missed this earlier in a post)?

Hello Blacky, thanks for the response!

I actually got out there this morning and removed and cleaned my EGR valve (was really dirty), I also removed the TPS to clean the pins and set it which I will be heading back out to do shortly. Also the ports into the EGR valve spacer were really dirty, I cleaned them as best I could. Should I remove the whole spacer or should cleaning the ports have done it?

Also I did actually get a code for the TPS, 63.

In the process, I have discovered that my crankcase ventilation tube has a 1" crack and needs to be replaced. The car has been running very rich as well so I hope replacing this will help with that as well. Is there a specific type of tubing required to replace said tube?

Also, I had read somewhere if you blow through the EGR valve from the flange side and it leaks it needs to be replaced. I blew through it with a hose but and the smallest amount of air escapes but when I push in the pintle valve lots of air comes out. Do you think my EGR valve should be okay once re-installed even with the slight air passage? I have a new EGR position sensor as well but if it runs okay I want to return it for the $85.

Thanks for the input guys, feels great to have a garage to be able to finally wrench even if it does flood when it rains a lot, which is all the time!
 
The proper way to test an egr valve is with a hand pump vacuum tester. Pump it up about 10 inches or so, it should hold on guage if diaphragm is good. As long as you clean egr well, and it works and holds. Save your $75.00 for dinner.


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