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find all ground wires in your vehicle clean and sand shiny , replace tight. will save money on parts you don't need. also older starters will begin to draw too many amps and keep blowing fuses. test starter.
have you checked that the starter itself has not been grounded out (short in the wiring?) The chances are this is what is causing your problem, start at the starter motor & follow the wires, check every single one, if you have a bare section that comes in contact with the body or anything else metal it will ground out that wire & cause the fuse to blow every single time even if you were to double the fuse resistance I.E. if the fuse is a 20 & you put in a 40 it will still blow - that last part is ill advice - never put a higher amperage fuse in a socket that was intended for a lower amperage fuse - it could cause a fire & serious injury, check all your wiring from the starter you have a short in the system somewhere it's just a pain in the a 4rse locating it
you have a SERIOUS electrical problem. - '.
BUT which fuses keep blowing - that is where we need to start.
1. is it the ignition circuit. - - does starter motor turn over when you trun the key.
2. is it the starter relay circuit.
3. is it the starter motor circuit.
4. is it the computer circuit. - - do you have fuel pumping to the engine and cylinders.
5. none of the above. - - do you have spark at the spark plugs.
The 40 amp maxi fuse in the underhood junction block (According to the information I have, there is only one 40 amp fuse in there..) goes directly to the ignition switch. From there, it goes to the buss bar in the Instrument Panel Fuse Block where it feeds several smaller fuses. It also feeds the starter relay in the Underhood Fuse and Relay Center.
My biggest concern would be: What caused the fuse to blow in the first place?
If you get nothing else from my preaching, get this:
Fuses don't blow for no reason....ESPECIALLY not a 40-amp Maxi Fuse!
I can't count how many times I have heard people say: "It's JUST a blown fuse." WHAT???
I have been at this for 35 years and I can tell you that blown fuses are reason for major concern in my book. That 40-Amp Maxi Fuse just saved your truck from burning to the ground and you need to find out why!
The only way that fuse is going to blow is if there is a direct short to ground between the Underhood Fuse and Relay Center and the Instrument Panel Fuse Block (The only "component" between these two is the ignition switch.) or if the secondary side of the starter relay circuit is shorted to ground. The secondary side of the starter relay feeds the "S" terminal of the starter solenoid. (at the starter)
I think the first place I would look for the problem would be the circuit between the starter relay and the starter. It is likely to be shorted against the exhaust or engine block. If this is the case, it most likely fried the starter relay in the process. (which is why the fuse no longer blows and the engine no longer starts)
Aftermarket remote starting units are also usually tied into this circuit. If your vehicle has one of these, it could very likely be the original source of your problem.
At any rate, there should be no rest, truck running or not, until the reason for the blown fuse is found. You will most likely get the truck running in the process of locating the reason for the blown fuse.
Fuses only blow if-Old,Overheated or you have a Short circuit.
That should be any easy fix,to the extent that there aren't many 40 Amp Fuses and you will need a wiring diagram to follow the problem from the fuse to the cause. If you know what fuse it is, you can guess,but I wouldn't recommend that,it will be time consuming and maybe costly ,if you don't have a test procedure to follow and throw parts at it.
Don't replace the fuse.Their expensive and will keep blowing.
make sure of two things one is any wires touching at the starter to ground or melted and or is the starter drawing too much amperage causing the fuse to blow.starter may have a dead short in it.
I'm sure there's a short somewhere, but I can't find it. I've even replaced the starter and it is still doing it..???????
The wiring that fuse protects is shorted to ground ! You don't know how to find a short ? Your best bet ,take it to a shop that can . Finding The Source Of Electrical Shorts In Your Car
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