As stated, vehicle is a 1994 B350 maxi-wagon, 5.2 auto, RWAL, 2wd.

Vehicle was acquired by a local county as a passenger van and converted into a coroner's van (read: dead people transport) I purchased it 2-3 years ago with 84k miles and some change. Vehicle is 100% mechanically stock. County maintained the majority of its life, which I too have kept up.

The county did add some wiring for a radio, emergency lights, strobes and wigwags, etc which was removed at the time of sale.

It's run perfectly up until 2 days ago. On the way home the dome lights started to flicker on and off at which time the dash lights also went out, along with the running lights, brake lights and turn signals... at first when I hit the brake pedal the dome lights would go off and everything would come back on. That lasted for about 5 minutes at which time everything stopped working and the dome lights stayed on all the time (even with the doors closed, ignition off, etc) now when I turn on the turn signals (if the bulbs light up) the dash lights and dome light flicker in relation the bulb. The abs and parking brake light also came on and stayed on.

Today I as I was driving down the highway the van cut off randomly and stayed dead. No fuel pump, no nothing. Right before this, the gas gauge started freaking out, going full sweep up and down and when it finally stayed down thats when it died.

All of the relays still energize (turn signal, relays behind the dash, etc) I've checked all of the fuses which are good and in their respective positions. I have also pulled the dash panels off and traced all wiring from the front seats forward and have found no shorts, no loose connections, everything under the firewall is as it should be. The county also installed a battery master disconnect switch which I normally use when it sits for long periods of time but now it's the only way to get the dome lights to stay off.

Battery also tests good, as does the alternator. Check engine light shows no codes

I'm simply out of ideas... Next step is to pull the steel dash shell and go from there. Like I said this van has been excellently maintained its entire life and I have never had one issue mechanically or electrically.

I need this thing running as I have motors and cars to move and I'm working Formula D @ Road Atlanta next week and the van will be a track support vehicle so I absolutely need it done.

I am open to all and any advice and as a final resort am debating about going to my local dodge dealer and letting them take a crack at it.

Thanks in advance

 

I really don't have a clue, but the last time I had weird electrical problems, it wound up being the ignition switch.

 

Could be the ignition switch since it does control the lights outside and inside of the van.

Electrical is very difficult to find the root problem when it's all over the place.

One known item to note is that the voltage regulation for the charging system is in the PCM. So, changing the battery and alternator eliminates those as the problem.

Another item is the ground straps from the engine to the battery. there should be at least four of them. One is located near the alternator and ignition coil to near the PCM mounted to the body. There is another near the engine to tranny back to the body. Another near the battery to the body and I can't remember where the fourth one was. But that's a start to check out.

As for the gauges on the dash and the lights having issues together, there is a BCM that handles the cluster. There is a method of holding something and turning the key "maybe" to run a cluster gauge test for the BCM. the BCM talks to the PCM of our vans.

One last item is to hunt for that not to obvious short. errrrr. That is a pain.

 

I would start with checking the headlight switch, a lot of the light wires go thru the switch.

 

that would not affect the random shutdown/no start issue

I've tested all of the relays *that I can find*

the real problem is the county left a lot of wiring behind, that they just cut when they removed components... so im having to weed through lots of dead end wires... and a lot of un-terminated connectors.

Also, my manual keeps referencing both a power distribution block and the fuse box...
I've back-traced both batt. leads and none lead to a "power distribution block" unless i'm just blind.

 

94 had fuse links behind the brake booster. The PDC was not introduced until 96.

 

ThAt could very well be my issue, maybe.

When you say behind the brake booster do you mean under hood or under dash?

Thanks

 

Under the hood, wrapped in electrical tape.

 

yea i found them... I have that same manual and its completely worthless... wiring diagrams arent really of much use if this thing still have fusible links...

I continuity tested all fuses with the ignition in all positions, 13 and 14 have no continuity regardless, which leads me back to what the manual calls maxi fuse 6, the 60a one... but i dont know what that is in fusible link speak...

I also did the stretch test and one just popped out....

none of them look physically blown but i've never dealt with wire type links... all my race and street cars have breakers and fuses.

If I can track down what is what (without an oem service manual its probably pointless) I will replace all of the links with real fuses, this link crap is for the birds

 

ok, what i've figured out is the white fusible link is bad (ecu, from what I can tell) so that would explain the random shutoff issue.

What I cannot figure out is which fusible link is responsible for the lights?

I guess tomorrow i'll start replacing these archaic pieces of wire with real fuses and hopefully solve and avoid this problem in the future all at the same time