Botched Wiring Bundle Repair

[ScottsGT]

I had the warranty repair done on my car just before the 36K warranty ran out. About a week ago the camera again went out with the warning screen. Fortunately for me, I work with several electrical engineers and field technician. One of them opened up the wire harness and low and behold not one but three wires were broke. One is the mini coax to the satellite antenna (not a big issue, don't use Sirius XM). The repair is very poorly done and appear a hard plastic sheeth was installed in the upper end of the loom. This was the point of failure for all three wires - in other words, this CAUSED the other breaks. Don't know if this is part of the TSB but, the placement of this sheeth made the wires break. Originally I suspected the break was where they zip tied it to the trunk opening. Anyway, we jury rigged a repair and the camera is back in operation complete with guideline. Tomorrow when it is cooler and he has his tools, we will make the final repairs. If someone has a copy of the TSB, I would love to see it.

See, here's the problem. This kind of repair needs to be handled by an electronics technician/engineer, not a mechanic. Video signals and digital transmission/reception is beyond the scope of a guy trained to be a mechanic. I am an electronics tech by trade. I guess I'll take this one on myself instead of letting a competent mechanic do something he's not trained to do.
If Ford was swapping the entire harness and providing a new mounting solution anyone could do it. But when you are talking about soldering, especially video signals, it's a specialty.

Sponsored

 

[SterlingStangMan]

I'm blown away by the fact that it was a six in piece of plastic sheething that caused the sharp that broke the wires. Had they not put this inside only part way through the lenght, the original repairs would probably have been it. Ford, if they specify this in the TSB, is setting us up for a future failure much more extensive than the original problem. If this is the dealership's "added value", it is almost as bad. Either way, agree with Scott, take it to an electronics specialist and get it fixed right. Best solution, Ford should have replaced the wire harnesses instead of putting a bandaide on it.

 

[wildcatgoal]

Pretty sure you just had an incompetent tech or the dealer let some random child fix it who said he installed a car stereo once when he worked at Best Buy.

 

[HISSMAN]

Cut all of the wires. Solder them together. Heat shrink and a new fiber loom. That is what I would do. But I am anal and do wiring electrical stuff for a hobby.

 

[SterlingStangMan]

And that my friends is who is working on our cars LOL!

 

[GTP]

Sorry to repeat myself, but as I said in post #9 (and #11), I recommend non-soldered butt splices, and be sure to ask for the electrical tech.

 

[VinnAY]

I tried splicing my stuff back together crimped (vs solder) and it's no better than it was which has led me to believe its broken in more than just that one spot. and of course if the tech secures it in the same place under the shelf its of course going to just break the repair...base problem here is the harness is too short.

 

[ScottsGT]

Sorry to repeat myself, but as I said in post #9 (and #11), I recommend non-soldered butt splices, and be sure to ask for the electrical tech.

You are correct. Soldering in high vibration/movement areas can cause wires to break at the edge of a solder joint. Crimping with heat shrink applied with several layers for support is the way to go.

Sponsored