Originally Posted by TJP



Watch video 1 VIDEO 1

pay particular attention around 4-6 minutes where he demonstrates little resistance but that is with no load and the commentary that follows.

video #2 VIDEO 2

this is a very simplified example to locate voltage drops. There are more videos on you tube

i would start at the battery. Using you're schematic follow the Voltage from the battery checking EACH connection along the way.

the + battery cable carries the V to the Starter motor lug. Sometimes a separate wire off the battery carries the ACC /RUN/lights etc to the starter relay. other cases the wire comes from the starter motor lug .

There is normally a fusible link between the relay and bulkhead connector.

out of the bulkhead to one side of the ammeter

out the other side to your Splice.
out of the splice to the various components some of which are live all the time (lights) others through the ignition switch. MOST but not all will go through the fuse box.
This is difficult at best but Tenacity will win.

I alos wanted to comment on the bulkhead connections. on the male tabs some are visibly making connection evidenced by the female terminal scrape marks. others are not showing those marks that I could see
beer







Thanks for sharing the links to those vids! I understand that those checks need to be done with everything hooked up and under load so that's how I performed them! I haven't had much time to work on the van but I started on it yesterday and I found a spot where I found a 0.8v drop/loss... Assuming I did the voltage check correctly!

I have 3 wires/cables coming off the positive side of the battery...
One cable goes directly to the starter motor and there's a smaller wire that comes off the starter and goes to the relay...

The second wire runs through the bulkhead and into the fuse block and is the 'hazard warning flasher'...

Please refer to the pictures of the diagram for this next circuit!... The third wire(S1-10RE) off the positive side of the battery runs up and goes into a splice which turns into a black wire(R6-10BK), from the splice to a "branched" section of fusible links where the wire turns into a small green wire(J2-18GR) through the fusible link and turns into a Red/black wire(J2B-12RE/BK) which runs into the bulkhead (#24) through the firewall up into the ignition switch harness! From the harness connection turns into a red wire(1-12RE) and goes into the ignition switch! The voltage drop I found is in the section between the splice and the connector(#24) on the interior side of the bulkhead and that's as far as I've gotten... I'm going out there in a minute and will be working on it all day!
Here's a bit of info about the circuit I'm talking about... The section of fusible link(J2-18GR) burnt out a while ago and what I did was install a glass fuse by tapping into the black wire(R6-10BK) right before the 'branch' of fusible links and directly to the red/blk wire(J2B-12RE/BK) that goes into the #24 connector in the bulkhead..... I ran a 'jumper' wire from the splice directly to the wire(J2B-12RE/BK) going into the bulkhead got an even bigger drop of about 1.0volts!....

I've gone and cleaned all the male connectors with sand paper but the female connectors are harder to access! I don't have anything that'll fit in there to clean them out. These terminals are very difficult to pull out of the bulkhead connector and some of them have a rubber plug around the wire so that I can't even insert anything to 'unhook' them from the little tab that locks them in! I feel like I'm just going to end up breaking the plastic!!!

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