1991 Cummins 4X4 Wiring Issues
 

Hello all,
My name is Rob and I'm trying to fix my father's truck. Last winter I was driving it and all of a sudden there was an electrical surge and the truck stopped running and would not start - completely dead. Smoke came out from under the dash. I replaced the voltage regulator which allowed the truck to run after replacing the batter but since then I've had a number of issues. Here they are

1. No head lights
2. No turn signals (the front stay on without blinking when I press the turn signal handle and nothing comes on at the rear). The hazard lights DO work.
3. Windshield wipers run continually - had to pull the fuse.
4. Alternator will not charge the battery.

Here's what I've done to try and fix the problems.

1. Found what I think was the short (push button that turns on the dome light in door jam - bare wire was touching metal). replaced all the yellow - melted - wire under dash.
2. Replaced turn signal switch at steering column, tested alternator (good), new battery, replaced voltage regulator.
3. Checked wired fuses on main wire between battery and firewall (they look ok to me).

Still did not fix anything, although the buzzer now comes on when I open the door. Does anyone have any ideas or do I need to take this thing to a real mechanic? Thanks for your time it is greatly appreciated. Take care and have a good day.

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My father's truck is a 1991 Dodge 4X4 5.9L Cummins

What part of the country you in? A good wiring diagram would be a go start to help. need to check the fuseable links again with a meter some times they look ok but are burnt inside

Great advice, thanks for responding and trying to help me. I'm headed out to check the fusible links again with a meter. I necked down the problem with my wipers, my intermittent wiper relay is fried, stuck on. Hard to find the relay, checked the local junkyard but someone beat me to it. Think I'll try to wire a toggle switch as an quick fix, pulling and replacing the fuse for wipers is a pain. Thanks again for your help, it is greatly appreciated. Have a good day.

Why don't you check the dealership they may have what you need.

I have the wiring diagrams for the 91.5 if you want them. PM me an email and there yours.