OH, THE HORROR! A green wire.

[Wayne M.]

I was under my truck today, I found something quite disturbing.



This is a wire I have never disturbed. A sealed connector. The corossion is actually eating through the insulation. It's a poor picture- the wire looks to have a pimple on it... ready to pop.

I can only wonder what else is going on in this truck. The good thing I guess is that it's the component side and not the harness side. There are is nothing wrong with the truck, no MIL, no overheating etc. I haven't settled on a game plan yet. I'm thinking of skinning the insulation, cleaning best as possible, then recoat with liquid tape stuff.

 

[cerberusiam]

Salt, its a wonderful thing for seasoning and preserving.



Not so good for wiring and metal parts.



Luckily thats just the fan harness. Hope the rest of it is better.

 

[Teich]

Not nice, wire got a hole in it poked for current test or cracked then the salt finds the hole and you have green stuff. Cut the wire at the "pimple" see how far the corrosin has gone in the wire, may have ot remove from the coupler and replace from there until you find a spot with no green brown or black stuff. Find one of the crimp connectors, the real short ones with no insulation about 1/2" long, find heat shrink tube right size, get the one with glue inside,use same color wire looks better, new end and seal for plug put it all together(shrink tube on wire before last crimp) heat the shrink, tape up the whole thing and it will be nice. Not nice things but can be fixed, good reason not to peirce wire to find power. Laurie

 

[steved]

The good thing I guess is that it's the component side and not the harness side.

This means nothing... unfortunately, the wiring isn't always that simple.



There is a wire on the 03/04/04. 5 trucks that will rub through on the head of a bolt exposed at the AC compressor... it will cause running fits (stumbling, rough idle, etc. ) because of the short. Turns out, one of the AC control wires also carries the crank/cam position sensor signal.



Something to remember...

 

[mwilson]

Wayne,



This might an option, that way you can make the splices back aways.

the only thing is this is for an '05. Star doesn't show a kit for the '04 trucks.



Unplug yours and see if it is the same style. Also check your wire colors.



Mike.

 

[WalterJ]

Carefully strip insulation, gaining access to copper conductor. If practical, cut out corroded portion, slip on some "sealing shrink tube" and SOLDER to repair conductor.

Good Luck.

 

[Wayne M.]

Wayne,



This might an option, that way you can make the splices back aways.

the only thing is this is for an '05. Star doesn't show a kit for the '04 trucks.



Unplug yours and see if it is the same style. Also check your wire colors.



Mike.

Mike, Is this complete with the wires assembled in the connector, unfinished - to splice in?

 

[Wayne M.]

I am quite experienced in dealing with sprouts like this, it's just I wasn't expecting it there, that way, on my baby!

See, I still think it's new

A good section of the vehicles I work on live in and around road salt. That's why, when I saw it my eyes bugged out. That was a virgin wire- definetly never probed for current. Possibly cracked from being in the elements.

It's ironic because when I first got the truck and upon inital inspection, I criticized that spot of harness right there.



I haven't decided on a repair yet. Mike may have the answer.....

 

[mwilson]

I have purchased a few of these kits for different applications and those came with about 10" of wire.



Had one of each colored wire, each wire had the terminal required to mate with the plastic connector on one end.

Also had the plastic connector loose in the bag.

You snap each wire/terminal into the plug as the color code dictates and splice the loose end to the existing wires.

Makes a nice repair.



Maybe Bob 4X4 or sag2 will add to this, they should have an assortment of these out in the shops in a big plastic case.



I know my dealer has them.

I don't go pawing through his anymore since I found the Mopar Connector site.



Mike.

 

[Wayne M.]

I have purchased a few of these kits for different applications and those came with about 10" of wire.



Had one of each colored wire, each wire had the terminal required to mate with the plastic connector on one end.

Also had the plastic connector loose in the bag.

You snap each wire/terminal into the plug as the color code dictates and splice the loose end to the existing wires.

Makes a nice repair.



Maybe Bob 4X4 or sag2 will add to this, they should have an assortment of these out in the shops in a big plastic case.



I know my dealer has them.

I don't go pawing through his anymore since I found the Mopar Connector site.



Mike.

Mmmmmopar ccconector site??! *going into convulsions* Please tell... I know Ford has a 20 page flip chart of connectors.

 

[mwilson]

Start here... .

Mopar Connector Repair Kit Website



Then select year and model.

Then hit the "pick this vehicle" button.



New screen appears.



If you want to see all applications just hit "go".



For example the '04 diesel fan connector is listed as a "Vistronic Fan Drive (Diesel)- DK Gray 6 way".

It will open up but tells you that there is not kit available.



Change vehicle in the upper left hand corner to an '05, now it is listed as "Drive-Fan-Radiator (Diesel) - DK Gray 6 way.



Open that and part number is given along with picture of connector end and wiring/color diagram.



Pretty cool stuff, eh???



Plus if you are working with the trucks wiring diagram you can find connectors by the C- number shown in the service manual.

Double cool... .



Let me know if you have trouble, it is a little finicky on some computers.



Mike.

 

[Wayne M.]

Thank You Mike! I had to get the plug ins and it works! I see about N/A in 2004, but I cant see an image either to compare to the 05. I'll have to go under and see. I think the best repair is to just replace the one wire. remove from the connector and splice in a new match.