About three weeks ago I used jumper cables to charge my Jeep's battery from my Dodge (passenger side battery). A few minutes into the charge my truck hood closed, it sounded like an arc welder going off under my hood. The hood support was sitting on top of the positive jumper clamp. The truck has been fine while using as a daily driver since the episode. Maybe a little slower to start. One connection from one of the heating grid relays next to the battery showed signs of melting. 250 heating grid relays are on backorder nationwide according to Dodge.

This morning I started my truck (plugged in all night) and a CEL appeared and it sounded like it was missing from time to time during the warm up. The engine had loss of power on hills and the volt meter was slowly moving back and forth. I returned to my driveway and parked. The display showed a P 2149 code, and the Security Light flashs continually with key in the off or on position and the doors closed or open. The interior lights were working when the door was opened and turned off when closed. I disconnected the batteries this morning and returned this afternoon.

Both batteries have over 12 volts per battery but when connected I have no power to the interior of the truck. The only thing lighting up is the Security Light flashing. The truck does not have a security system. And the positive battery post has the same pulsing from acid between the battery post and the connection. New Mopar batteries installed 11/2011 and black key used since purchased in 2005. Any ideas would be greatly appreciated.

 

I'm wondering if ECM? I was told by an alternator rebuild shop that the voltage gauge is controlled by the ECM. The alternator does not have a voltage regulator.

 

One quick thing to try is to disconnect both batteries and let them set for a while. Then, touch the positive and negative cable ends together to remove whatever charge is still in the various components. After it's sat for a few hours with no power, reconnect and see if it cleared things up.

 

Do you mean the positive post is loose and there's acid coming out around the top of the post? If that's the case the battery is probably toast because the post has broken off inside. Leaving the grid relay plugged in and driving the truck probably isn't helping either. The electrical systems on these trucks are not very forgiving. If you have a problem you have to correct it immediately or park the truck until you do to keep it from snowballing.

 

Installing new Mopar batteries this evening.

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2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit

 

Keep us posted on what happens. I've got an electrical bug myself and am in the process of trying to figure it out.

 

Update - New batteries installed. Installed the positive side on both batteries first. Then the negative connection on the passenger side. Had some pretty good sparks from the negative post to the cable connection when applying the battery cable. Then no spark on the driver side negative connection. Checked for codes with the turning of the ignition key three times. The display showed 2149, 2146 and 2509. No security light and the interior lights came on this time. Then I disconnected both batteries completely in the reverse order. Next step is to change out battery cables while checking for exposed wiring and the heating grid relay in question.

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2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit

 

P2146 Bank 1 (Cylinders 1-3) Shorted High Or Low
P2149 Bank 2 (Cylinders 4-6) Shorted High Or Low
P2509 Ecm/pcm Power Input Signal Intermittent

I think you're going to need a scanner to clear the codes and see what happens next.

 

Thank you Totallyrad.
Please redirect me if I am assuming too much.

- So codes continue to be displayed, and stay in the truck's memory after a change (part/alteration) until cleared?

- A battery disconnect does not reset the truck's computer to reassess?

A scanner would probably be better than the stock three turn ignition key code display. Any scanner or brand recommendations for a shadetree mechanic new to working with an automotive computer?


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2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit

 

Some codes, referred to as hard codes, have to be cleared by a scanner. Locally, I can borrow a scanner from several local auto parts stores and run home and clear the codes, then see what pops back up. Of the 3 you set, some of them may clear with the scanner and stay gone now that you've got the new batteries. You'll just have to work through this one problem at a time. BTW, if you someone with a programmer like a Smarty for a 3rd gen they can clear the codes for you.

 

The arc and the damaged battery set those three codes. The codes may go away after a certain number of starting cycles if the problem is fixed and it doesn't happen again. Of course it's best to clear now so you know whether the problem is still there after doing the fix.

 

No luck finding the intake heater relay from Dodge or local salvage yards. Anybody know the amp specs and if the relay works all the time or part time? I need to find an alternate relay until the relays are available. The relay was used from 2003 - 2005.
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2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit

 

Part # 5086631AA

__________________________________________________ ___________
2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit

 

The relay is back in stock with Dodge.


__________________________________________________ ___________
2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit

 

The new batteries and relay did the trick. Cleared the codes and they have not reappeared after starting and driving around five times. Thank you all for the input.


__________________________________________________ ___________
2003 SLT Quad Cab 2500 Short Bed, 5.9 H.O. Humming Cummins, 6-Speed Manual Transmission, 2 Wheel Drive, 3.73 Drive Axle Ratio, Stock Unit

1988 F250 REG CAB/LONG BED, 7.3 IDI DIESEL, C-6 Auto, 2 Wheel Drive, 3.55 Drive Axle Ratio, Stock Unit