What's this box on the bulkhead?

cornishboy1990 · May 20, 2012

Hi there! Had my '75 series 3 for about 2 years now, I am a complete novice when it comes to engines/electrics but things are now starting to go wrong and i'm having to learn

Just a quick question, does anyone know what this black Lucas box is attached to the bulkhead? When I turn on the heater plugs it begins to smoke followed by a smell of burning just wondering what's occurring.

Any help greatly appreciated!

dellboy1959 · May 20, 2012

If memory serves correctly,it's a ballast resistor but I'm sure someone on here will jump down my throat if I'm wrong

jamesmartin · May 20, 2012

it ballast resistor ,glow plugs are 6 volt supply to resistor is 12v

mistericeman · May 20, 2012

Is he not on about the relay ????

cornishboy1990 · May 20, 2012

Yea, talking about the little black box to the left of the ballast, any ideas why it's decided to smoke though?

jamesmartin · May 20, 2012

mistericeman said:
Is he not on about the relay ????

looks like it didnt see that just looked at obvious

,its not std obviously fitted for some reason maybe faulty resistor ? trace wiring

mistericeman · May 20, 2012

Probably a relay for the glow plugs ....
either it's knackered OR too small to handle the current the glow plugs pull OR a fault with the wiring to it OR fault with the glow plugs

mistericeman · May 20, 2012

jamesmartin said:
looks like it didnt see that just looked at obvious,its not std obviously fitted for some reason maybe faulty resistor ? trace wiring

WHY would that make the relay smoke when he operates the heater plugs ???

dellboy1959 · May 20, 2012

cornishboy1990 said:
Yea, talking about the little black box to the left of the ballast, any ideas why it's decided to smoke though?

Not easy to see but it looks like a relay.try tracing the wires and see where they go.

cornishboy1990 · May 20, 2012

Thanks guys will have a look at where the wires go, prob will need a new one of whatever it is

jamesmartin · May 20, 2012

its not a std part so perhaps fix what it is replacing ?

cornishboy1990 · May 20, 2012

There is a wire going to the black button that operates the plugs and one going to the ballast then another to the battery, dunno if its to small to handle the current as it's been fine for 2 years

dellboy1959 · May 20, 2012

cornishboy1990 said:
There is a wire going to the black button that operates the plugs and one going to the ballast then another to the battery, dunno if its to small to handle the current as it's been fine for 2 years

Gotta be a relay then,It could be bad connections but replace it anyway for what they cost.

cornishboy1990 · May 20, 2012

You reckon a relay from a 200tdi defender will do the job?

dellboy1959 · May 20, 2012

To within reason a relay is a relay.Their job is to act as a secondary beefed up switch so as not to burn out the operating cab switch so i would say give it a go and see what happens but have someone looking under the bonnet to keep an eye on it when activated.
One things for sure,the old one's a potential fire if left unsorted

cornishboy1990 · May 20, 2012

yea i don't want any fires! will give it a go thanks for all advice!

johnny curt 1 · May 20, 2012

the bracket next to the relay should have a large spring on the back of it if not you need a new one of them

now the big red wire on that bracket should be on the other end of that bracket then the thick brown wire with a yellow stripe should be on the left terminal of the bracket thing along with the thin brown wire and the green wire with the white stripe goes to the bulkhead

as per original to the vehicle wiring the relay doesnt need to be there

hang on ill get a pic of mine

johnny curt 1 · May 20, 2012

here yer go fella

cornishboy1990 · May 20, 2012

So if it's wired up to the bracket correctly i don't need the relay?

johnny curt 1 · May 20, 2012

cornishboy1990 said:
So if it's wired up to the bracket correctly i don't need the relay?

as long as the spring thing is ok on the back of the balance resistor bracket and not shorting directly to earth normally the 2 bolts through either end of the spring are insulated with 2 bakerlite washers or similar

What's this box on the bulkhead?

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