Connector Fire

[Jason 3500]

I was idling truck (2003 3500 SO engine, auto) unloading some trash, noticed an electical fire smell, and sure enough, it was my truck. Went to cut engine off, noticed gauges were haywire. Not much smoke, opened hood, saw small flame on drivers side behind the engine. Quick squirt from fire extinguisher put it out. Was able to start it back up and make it 10 min back to my house. Gauges seemed normal.



There is a couple large connectors mounted near or on the bellhousing, drivers side. All were nicely mounted to a good beefy bracket. Ends up a ground wire rubbed through a wire near one of the connectors, arced, and caught the wire insulation and connector on fire. The connector is shot and needs to be rewired. The ground wire is about 90% gone where it arced.



This really pisses me off. The ground wire is not insulated, one of those woven strap type, about 18" long or so, and I cant reach where it connects to the engine block or bellhousing. I cant believe Dodge would have an uninsulated wire dangling over 20 or so other wires and why it needs to be so long. To me this was an enevitable event, granted it took 170k miles and 8 or 9 years, I still think the placement of this ground wire was irresponsible on Dodges part. I searched a little last night and didnt find any other occurances or recalls, didnt find anything but I am going to search some more. I just wanted to rant some and see if anybody has heard of this beng an issue. Also, does anyone know where I can get another connector like this, other than junk yard? Hopefully I havent fried anything else.

 

[E7mack96]

it looks like the connectors on freightliners. . (used on the engine for fuel injector harness and another harness) so i'd give then a shout.

 

[Bob4x4]

Was the trans harness conector secured properly in its bracket or was it dangling by the wires alone?

 

[Jason 3500]

It was secured properly.

 

[rbattelle]

This is great info. Can you post a wider-angle shot so it's easier to tell where on the truck this connector is located?

Once we figure out exactly which connector it is we can post a diagram of it so you know how the wires are supposed to connect. Then use any connector you want (custom job).

Also - please consider notifying the NHTSA safety office of this incident!

-Ryan

 

[Jason 3500]

This pic should show location. It is looking towards the front of the vehicle. The bolt heads in the foreground are for the trans fluid pan. You can see where the ground wire attaches to the body on the left (drivers side). There are two connectors mounted on the bracket. The one that shows the best is the bottom one. The one above it is the one that got fried. This pic was taken after I started messing with it, so the connector is not attached the the bracket correctly, but was originally. You might be able to see the ground wire hanging over the connector.

 

[Jason 3500]

Closer pic.

 

[Prairie Dog]

If it's going to cost much you may want to notify your insurance for comp coverage.

 

[rbattelle]

I'm thinking that might be connector C217. If so, there shouldbe 14 wires in it and it's right next to another connector (C216) which has only 8 wires in it.

-Ryan

 

[Jason 3500]

This one has 11. Decided to cut it out and repair it. Only one wire had a couple strands broken, soldered it solid, then put shrink tube on all wires that the insulation burn. Epoxied everything shut with a two part 'plastic bonder' epoxy. Hard part will be wiring it back into the harness with limited space. And keeping my fingers crossed nothing else fried.

 

[Jason 3500]

Got it all wired back in. About two hours of driving over past two days. No issues, no trouble codes. It was real easy to put a 1/2" wire loom around the ground wire that caused this. I would suggest anyone else with a braided, un-insulated ground wire to do the same. A friend at work has almost the same truck, I am going to check if his is the same.

 

[MLee]

So this may be prevelent with the 3rd gen trucks. Thanks for the heads up.

 

[TLane]

Have you ever had any transmission work done? If you have, the ground wire might not have been reinstalled properly. Just thinking it might not have been Dodge's fault.

 

[Rhett144]

ohh thats really horrible... ... ... ... ...
So what do you think its some kind of short circuit or some heating issue?
I have never face this kind of serious problem. You done very good job.

 

[Jason 3500]

I think I am the third owner of this truck. I do not know the repair history. I did not see any prevelant means to secure the ground wire. I am waiting for a coworker to drive his 2500 in, same year as mine, and another to check his truck, so I can verify what condition their ground is in.

Rhett144- Short circuit due to ground wire rubbing through insulation on a positive wire.

 

[RDHamill]

this might help http://www.repairconnector.com

good luck

 

[Jason 3500]

So I did end up checking out my co-workers truck, same as mine but a 2500, 2003 four door, 4wd, long bed, auto, single rear wheel. He has the same un-insulated braided ground wire rubbing on the wires of the top connector. I felt the wires going to the connector and the insulation is starting to get worn through. Fishing a 1/2 inch wire loom around the ground wire will solve this issue.

I took some pics of his wires touching. Been pulling 60+ hours a week at work. When a get another chance to come up for air I will try an contact Dodge and file something with NHTSA. I may be the unlucky fool that got the ground to touch the one main hot wire coming out of this connector.

 

[Lordsman]

Mine's doing the same thing. It's dark out, but with a flashlight and looking over the driver side tire through the wheelwell area, I can see that ground wire making contact in 2 places. I would have never noticed it until... thanks for the alert! Looks like a common problem.

 

[rbattelle]

I checked mine over the weekend. The ground strap is extremely light weight and was merely resting against the connector, with no visible degradation of the connector. But, better safe than sorry, I put a bit of wire wrap over the strap where it rests against the connector.



Gotta be a contortionist to get in there.



-Ryan

 

[SWithrow]

this might help http://www.repairconnector.com

good luck

Also here as well. http://dto.vftis.com/mopar/disclaimer.asp