High Voltage Surge

[Waterloo]

Get under the truck and check your cabling and wiring, especially where any exits the sleeper and along the frame rails. Secure anything you find lose or rubbing after inspecting. Also open the battery box and check to insure the connections are tight on the posts, and that all are connected as they are supposed to be, take your time and really look, I have missed connecting this one wire I have at times when working on the truck. Check your grounds, especially at the engine block, you should have one at your starter, you will need a flashlight. If you see any exposed cable, I would replace it, odds are it is green and not doing its job.

Then, it might be a good idea to look in the fuse panel, check the fuses for any signs of trouble, like scorching or melting. If you have a Prostar, there are fuses and relays under the hood and in the driverside sleeper compartment. Check those too.

Under the hood, look at the connections on your alternator, make sure nothing is rubbing or is exposed to the elements, a nicked wire, or connections are lose. I routinely check my wiring, from the firewall to the CAC. I like to use that liquid electrical tape if I find anything that has rubbed or any suspicious connectors and seal it from the elements. The stuff is fantastic, and can be used in a pinch. https://www.amazon.com/Permatex-85120-Li...rical+tape

If you find any wires or cables rubbing against something, you can either zip tie and secure them, or if you are not able to do that, wrap the cable or wire in some old heater hose and secure the hose around the cable or wiring with zip ties. This will protect the wiring or cable and let that old heater hose take the abuse. Just remember to secure it, and check periodically. Or, use this wire loom protector, I buy it in 100 foot boxes in various sizes... I was just under the truck and used about two feet of this and resecured a cable just yesterday. https://www.amazon.com/Support-Split-Fle...+protector

At the rear of the tractor, check your lighting connections. I just recently had to rewire my entire ass end. I had repaired it before from the previous owner, but it was to the point it was giving me issues elsewhere in the truck. I bought a Weatherpack connection kit from my local Car Quest Auto Parts store, here is the same kit http://www.jegs.com/p/JEGS-Performance-P...5/10002/-1

The OEM harness connections were shot, so I cut them off and installed the Weatherpacks, along with a new back up alarm. One thing I like to use too, is dialectic grease, you can get it in most auto parts stores. It is weather and waterproof. I like to get the large tube and keep it in a zip lock bag. Here is the stuff I use, great for outdoor satellite installs too... https://www.amazon.com/Dielectric-Waterp...ric+grease

Also, the dialectic grease, I like to use it on my battery connections, the posts, smear it on there, not to heavy, but enough to cover the nuts. It eliminates the corrosion at the posts, and is cheap insurance. And when splicing wires, if you do not solder and use but connectors, I use the grease or silicone caulk in the connection ends, insert wire and crimp, then use the shrink tube over that to seal from the elements.

Another thing, and this has been discussed numerous times here... It is a good idea to replace your fuses, as they lose their effectiveness over time. They do not blow, they just lose their mojo, especially these cheap Chinese ones. I have some of the mini fuses that I have to replace every few months, especially the one for my AC blower motor. These are the Mini ATM fuses, in 5A, 10A and 30A. I am also replacing all of the OEM resettable fuses, will pick them up tomorrow from the dealer... Having electrical issues myself... Narrowed it down to the fuses, I am replacing all, including the relays.

I just bought a box of each of these, Bussmann, better quality and a good price on Amazon...

https://www.amazon.com/gp/product/B004AH...UTF8&psc=1

https://www.amazon.com/gp/product/B004AH...UTF8&psc=1

https://www.amazon.com/gp/product/B009WQ...UTF8&psc=1

I hope this helps you. This is pretty much what I do when I believe I have electrical issues. So far so good, and I have not had to visit any mechanics for anything more than to slap their computer on my truck to tell me where to look, or what module to replace. Then I go home and fix the problem myself, to know it is done right and to inspect for other issues near the problem... They usually come in threes on my truck.

Good luck!