Amen to that. Even though safety is a concern, my worry would more be causing the glow plug tip to expand and the possible consequences to the engine.
My 2004 has the external fuse DIY fix. In all the years since it was installed I have yet to gain any benefit from the external fuses.
My 2006 has an internal fuse DIY fix. In my opinion it is a bit easier as to implementation, and less cost to boot.
If a glow plug/fuse fails I will just need to pop the controller apart again.
This is the entire procedure.
A method for replacing individual glow plug fuses within the old style module.
My wife announced she was taking the 2006 white truck on a ladies shopping trip. It's basically ready to go, but when the ambient temperature drops below 35F or so the MIL aka CEL lights because there is a bad glow plug. I know that makes her nervous so I decided to fix it.
My original plan was to replace all five glow plugs and do the Surly Old Bill fuse modification as I did with my 2004.
Bill's excellent modification is here.
http://www.sprinter-source.com/forum/showthread.php?t=6935
Actually since doing the fuse modification on my 2004 none of my fuses have blown. I had 2 ea. spare glow plugs on hand. I also have an assortment of spare Sprinter fuses. I could wing it.
I pulled the GP module. The case was sealed with a rubber like caulking. I don't recall that seal on my 2004. Anyway, I cut the sealant loose with a sharp blade. After that I used a small screwdriver to pry the side covers away while placing toothpicks around to keep the gap open. The cover eventually popped off.
I found #4 glow plug fuse open.
I cleaned the burned ends to add short leads with fully insulated slide on connectors. I used a 25 amp fuse.
The soldered leads.
The 25 amp fuse tucks in nicely. I decided to use a 25 amp fuse because I had a bunch on hand. I used 20 amp on my SurlyOldBill external fuse mod. It's really just there for short protection, not traditional overload protection.
It looks to me like at least 2 more fuses could be squeezed in if needed. By using the newer smaller automotive fuses a full complement of 5 might even fit.
Be aware that there is a newer style MB updated design glow plug module that trips and resets so the various types of DIY fuse mods can be avoided by purchasing the new style module. The newer module is somewhere north of 100 bucks.
Some of my previous glow plug information is here.
http://www.sprinter-source.com/forum/showthread.php?p=117395#post117395
The #4 glow plug removed from my 2006 hot engine like it was new. No problem at all.
vic
Doktor A's Glow Plug Test procedure.
Added:
The 2006 main relay contacts looked great. No real signs of deterioration after 10 years 148,000 miles. That service time was in southern PA though.
Parts Info
I'm quite certain that the new style module is Dodge 68079372AB
Europarts SD stocks the new style T1N Glow Plug Module (As of 12/2016 I think the picture in the listing is the old style.)
http://europarts-sd.com/glowplugcontrolunit2002-2006.asp
Glow Plug Relay Module Dorman 904-304
http://www.dormanproducts.com/itemdetail.aspx?ProductID=74038&SEName=904-304
Misc. Parts Info (Verify before ordering.)
Glow Plug Relay Time Control Module For 2002-2006 Dodge / Freightliner Sprinter 2.7L Diesel Engine (Replaces OEM 68079372AA, 5170859AA, 5103568AA)
Replaces 68079372AA, 5170859AA, 5103568AA, 51 299 029, A 648 900 00 00 0 01
Mercedes Benz / Sprinter # 6489000000 / 0005453616
Other Part Number: 68079372AA 68079372AB V30710031 37105 10937105
Manufacturer Part Number: A 000 545 36 16 0005453616 0255452932 0285454032
Interchange Part Number: 0195456932 6489000000 5103568AA 5170859AA, 05103568AA 05170859AA 68079372AA
A 648 900 00 00, A 025 545 29 32 A 028 545 40 32
Click on the blue arrow icon within the quote box to access the original post/thread.
vic
The external fuse holder WILL save me pulling out the headlight and cracking the module open again if I ever have another glowplug short to ground, but it could also be that this is a one time repair. I had four DTC codes (plugs 1,3,4, and one for an open circuit on module A), so the decision to replace all five plugs was obvious. While the pings and creaks made by 1&2 as I worked them free had me worried, plugs 3,4, and 5 came right out. When I opened my module it had three blown links, so the extra effort to bridge all five and run the leads to the fuse holder was minimal, if not strictly necessary.
