So I had an issue with no power. Wouldn't start. No lights on dash. Replaced batteries and alternator. Nothing. So poking around I found what's in the images below. Looks like part of a harness that goes under driver side battery and also goes under cab to the trans area. Hope this isn't going to break the bank.







Seperated. Located behind driver side battery. Looks like part of a harness that goes under cab to trans

 

I have no idea what it is but it looks seriously corroded.

 

Wow- That is nasty - Did battery leak on it maybe -

 

I have seen a thread with the same issue. If I remember correctly he was able to take it apart and clean everything up and the issue was resolved.

 

I hope it can be just cleaned. My mechanic said same thing but is on vacation. Sent him the pics. Looks like a very important wiring harness. My giess

 

Someone recently had this issue- it's just a junction block where a couple cables meet. I think it was a clean up, crimp on new terminals and go!

 

Fingers crossed that its just that. Did the previous posts have directions on how to do?

 

Maybe this will help!

https://www.ford-trucks.com/forums/1...l-failure.html

 

Thats exactly it...

 

Suggestions on what I should use to clean that? Where would I get the new connection

 

[QUOTE=tk1325;15507310]Suggestions on what I should use to clean that? Where would I get the new connection[/QUOTE
If you have the skills, you can use stuff from West Marine and build your own setup.
If not, I would look for an OEM junction block and fusible links for the easiest fix. Crimp on new terminals and go.
Once the corrosion is as bad as yours, cleaning the parts may not be the best answer, since the rust will keep going and so much material is gone...

 

OP, what year is your truck? Reading through the link posted, it seems this may only apply to the last 2 model years of our trucks.

 

Its a 2002

 

The thread Mike linked to was mine. If you watch the video, you can see the little box wasn't replaced. Al the wires were stripped clean and spliced together. That little box is there for assembly purposes. The stud that holds the box to the fender well allows a path for corrosion to get into the connection.

I was actually lucky. I was en route to pick up a car trailer when mine went. 20 minutes later I would have gone dark going 65mph with a loaded car trailer in tow.

 

That was an excellent thread. I think as time goes on this issue will appear more frequently on other trucks, unless addressed beforehand. Your thread may encourage people to take a look at their junction box during maintenance. It's hidden location could make it difficult to resolve when it fails. Problems like this seem to always show their ugly corroded face at the worst possible time.

GREAT JOB! Thanks again...