Any one ever had the grid heater relay stick or weld itself closed. I went to crank the truck this morning and the batteries were dead thought it was kinda wierd but nothing crazy, thought maybe I had left lights on so I got my dad to come jump me off with his 03 well hooked up the battery cables and let it sit there for a second to build the batteries back up since they were completely dead after about 5 mins I smelled something like hot wiring and start looking immediatly and see that the rubber boot on one of the grid heater terminals is smoking so I found a wrench and took the battery cables off quickly and jumper cables. It seems as though the relay mounted just below the drivers side battery stuck and was sending power constantly to the heaters and was what pulled the batterys down. I pulled the wiring loose from battery to the heaters and off the relays to the heaters. So that I can drive the truck and not burn it up until I can do some further checking. It was hot enough i couldnt lay my hand on top of the intake air horn for about 15 min and discolored it. Just curious if anyone else had seen this problem

 

anyone else had this problem?

 

Never had one stick on, but they are a relay, so I could see how it would happen.

Check the relay out with the grids disconnected.

Plus 12V to the small terminals is always there, the PCM drags in the ground to actuate the relay.