2005 F350 6.0l pulling 60-110amps
 

Hello,
My 6.0l International is having an issue with high amp draw.
It is drawing down my batteries and causing gauges to cut out and poor running condition.

When I start the truck and have it at idle I am seeing an average of 30 to 38 amp draw which is normal.
After 20 to 30 seconds it instantly and consistently will jump to 60 + amps and when the engine RPM is brought up it will climb over 100 amp draw.... BAD

To rule out obvious issues I have

-Replaced the batteries and all Power and Ground cables
-Ensured all harness connectors are clean with no corrosion and good contact
-Using analyzer checked voltage at ECM (14.2) as well as checked for codes and performed all tests (No codes)
-Tested the alternator and ensured no inconsistency of the internal voltage regulator
- Replaced the High Current Relay under the hood

Because of the delay I am leaning towards the GP Timer Module? or ??????

Please help

Have you verified a similar vehicles amperage numbers under similar conditions? I dont think there was a published spec in regards to this. Whats the failure? What made you look for a high amp draw?
I would start by unplugging the glow plug controller and monitoring the amperage. If nothing else it would rule it out. Then I'd likely use a amp clamp and work way back to anything with a high amperage usage. Anything thats using 60 amps or more is building heat somewhere. And if I its not popping any fuses that makes you think its likely a big wire that non fused which leaves the starter.

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I have a fleet of trucks at my shop with the 6 litre tested three to compare and all ran an average of 38 amps. I would agree on the starter except for the fact that the truck does not start pulling high amperage until 30 seconds of run time. This leads me to think it must be a short in a circuit with a timer or temp sensor switching it.
I started amp clamping the truck to source the draw. It was apparent there was a draw due to the symptoms of low voltage to the PCM while driving the truck ( gauges cutting out / high current relay clicking / poor running condition) much like starting a truck with over discharged batteries.

Its to easy to get stuck looking in one direction and missing the problem by not keeping a open mind. I agree the 30 seconds on the dot every time sounds like a timed response, however you could spend all you're time looking in one direction and end up missing the problem. Amp clamp the glow plug controller feed or disconnect the controller while the symptom is present. If it goes away then you're answer.

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