Title says it all. Trying to diagnose the cruise control, and pulled the sensor's plug and saw this.




You can see the sheen on the male part of the plug. What do you guys think?

 

That is the reason for the TSB/Recalls for the CC Switches. The Brake Fluid gets in the sensor and then the truck goes up in smoke...

So I vote leaving it unplugged until further notice.

Ford's genius idea for a "Fix" was to install 2 fuses. 1 on each wire.

Just letting you know, that, that particular issue right there has costed a LOT of OBS trucks to go to the JY's wayyy too early.

 

PM me your address and I'll mail you one of the recall kits for safety's sake.No charge. also replace the switch.

 

Barny, what do you mean by the switch? What does the retail kit have in it? I've seen part Motorcraft #sw6350 that is supposedly the recall kit and has the wiring and sensor included.

 

mine just did this too! i just went out and unplugged it. So when i go to fix this do i cut and splice a new female connector on it and then unscrew the old thingy mabober then put the new one on and then reconnect the connector??

 

that "sensor" is the cruise control brake switch.
it was a defective part from the manufacturer.
the recall is to replace the defective switch with a new one from a different manufacturer, and install 2 fuses in the wiring harness to the switch. this way if the switch does short out, it will blow one of the fuses instead of burning up the truck.

 

Right, the switch fails just like yours did and allows brake fluid into the electrical portion of the switch. The fluid shorts the contacts within the switch to chassis ground, and it eventually gets hot and starts burning.

First thing I do when I bring a new-to-me Ford home is pull that plug.

 

Texas Instruments did not supply a "defective" switch... it was exactly what Ford asked for.
Ford engineers were the ones that spec'd a Kapton diaphragm.
Of course, this plastic gets brittle when submerged in brake fluid.
They also didn't fuse the harness input... (because brakes should 'never' be fused)
Then they offered the first recall harness. (*the one that was fused on the downstream side*)
So, then they recalled the recall...

Friggin mess all around.

If you have fluid in there already you need to replace the switch, not just add the fused harness.

[url=http://www.flickr.com/photos/24183730@N03/2339567274/]

 

Do NOT plug that harness back in until you get that switch replaced.

 

The same Kapton that's been responsible for a few aircraft fires too. Older aircraft apparently used this as wiring insulation, and I was reading an article that explains once the insulation cracks and causes a flashover, the charred insulation itself becomes conductive. The next time the breaker for the affected circuit is reset, there's another flashover, of course with the associated heat and potential for fire.

I didn't know there was a second recall harness... I've only seen the ones with a single fuse and kinda took it for granted that it would be on the input side of the switch.
Wow... so much FAIL from Ford when it comes to this problem.

 

They make a flexible diaphragm from this stuff and expect it to last through (I don't know how many times you touch the brakes in the lifetime of a truck)

That happened to my neighbor Ben's truck at about 6:30 one Sunday morning.
Thankfully he was parked on the street and not in his garage.
The master cylinder was completely gone when the Fire Marshal came to investigate the 'arson'...


Edit to add link to my original thread; https://www.ford-trucks.com/forums/7...rol-fires.html

 

second recall harness has 2 fuses in it.

 

There's NO point in putting a fuse after the switch.
The plug is polarized, it can only be installed one way.
Just damage control. "There's NO WAY there can be a problem with our latest double down harness"

TI made the switch itself (to spec)... not the harness.
If you make one tiny piece of a complex machine do you have any say in how it's implemented?