Fixed my OD switch SHORT
3 Attachment(s)
Finally made time to fix this pesky little problem. I will echo the scores of X and Super Duty owners who have said repeatedly over the years to FIX this BEFORE the wires get chaffed enough to short... I didn't listen even though I knew about this when I bought the X and waited for it to fail :-X19.
The problem: The wires for OD switch travel thru the shift lever and after exiting they cross over the top of the column and plug into the wiring harness. Since these wires need to allow the shifter to move as well as the steering wheel to tilt - the wires also move when these things are moved. As the wires move back and forth this 1/4", they eventually wear thru the insulation and expose the wires. Initially, my OD lite would come on for no reason and eventually I was blowing fuses when shifting or using OD switch. As far as I can tell, THIS WILL HAPPEN TO EVERY ONE OF THESE TRUCKS - eventually. Seriously, its an EASY fix if ya do it NOW - it takes 20min, a phillips screwdriver and some tape! First, remove the (3) screws that hold the plastic trim around shifter. Unscrew the tilt steering lever and remove lower plastic piece. With ignition in 'on' position, press the little shiny ball on the bottom of key cylinder and remove the cylinder. Attachment 202621 Now you can slip the upper plastic over the shift lever and get it out of the way. Attachment 202622 Since I'm a dum redneck and waited until I had a problem, mine was worn completely thru one of the wires. I was trying to strip it back and repair it in place and pulled the other 2 wires apart where they were crimped at the hold-down thingy attached to this black trim piece. Attachment 202623 If I was smarter, I would have just unplugged the wire from harness and removed the pin in my hand and slipped the shifter lever, wire and black thing off so I could take the whole thing out where I could get to it... Don't try to slide that black piece off the shifter, its too big and will tear. This one was already torn and fugly - anyone got a part # for it?? I'd like to replace this one. |
4 Attachment(s)
With parts in hand, I sat down at the workbench and soldered the wires back together and covered them in shrink tubing.
Attachment 202617 This is a 2nd small chaffed area, I put enough shrink tubing over all the wires to cover this area as well. Attachment 202618 To finish the repair, I put shrink tubing over the the whole thing and put it back in the truck!! Attachment 202619 While I was in there screwing around, I found the black w/pink stripe wire that triggers the 'key in ignition' chime. I just unplugged the thing from the lock cylinder and taped it up!! NO MORE CHIME every time I open the door with the keys in. WOOOHOOO! All other chimes still work. I just taped up the connector thingy. I'm not sure why I was too much of a weenie to just cut the thing off and put a piece of shrink tubing over the end of the wire... :-roll Attachment 202620 |
Nice work my friend.
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Great write up Jason!
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Great write up with reps sent. Mine broke at the bottom of the shifter stem where the wires exit through the white nylon sleeve. I had to fully disassemble the shifter and fish new wire because there wasn't enough sticking out to reconnect.
Gread advice to service it before it breaks. It is a VERY easy item to check and very annoying when it goes bad. |
Thanks guys, it really was easy. It would've been waay easier to fix it BEFORE it failed though! :-X22
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Maybe we'll make you the official OD wire fixer at all the GTG's...lol
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I still had a lot of that factory grease around my wire when I pre-fixed mine so I greased it up good so the tape slides easy.
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Just put this on my fix list for the weekend along with reservoir tank replacement, serpentine belt replacement and radiator hose replacement. I'm glad you said it's going to happen if you don't fix it because being a hardheaded redneck I have to hear it ten times before I'll do it. Reps your way!!!
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Glad i found your post. Ive been having problems with blowing fuses for a year now. Found this forum a month ago and is amazing at all the same problems i have as everyone else. I found my worn wires right where you said they would be. took off the shifter solder wires together and works great. Thank you very much for the write up. Awesome to fix. Very easy
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I'm replacing the Shifter Boot in my '97 Aerostar which has torn, and found this How-To searching online which is very similar to what I'm dealing with.
by the way: the part number for the Shifter Boot (the black vinyl "thing") is XL3Z-3D677-AAB just in case you are still waiting to replace the torn Shifter Boot. the difference is that my OD wire harness runs down the steering column to I don't know where, still haven't found where it plugs to, and I am not going to undo the steering column to find out. I'm thinking of cutting the darned harness and then soldering the wires after I slide the new Boot into the shifter arm and wire harness. What a hassle! Or maybe try to find a small 3-wire plug with male and female ends to make it easier in the future to remove the shifter arm and OD wire harness. why didn't Ford think of this? I am also saving the old torn Shifter Boot Frame to make a new boot out of a different material that does not tear, maybe leather, but definitely with more material, since the factory part has less material than it needs to have in order to move and stretch properly. Thumbs down to Ford on the design of this part, it appears that every Ford truck has the problem of the torn Shifter Boot. |
I wanted to let you know thanks for the post! I taped the wire harness of the shifter and ran the harness under the shifter and then clipped it back and wanted to know if I did wright?
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I thought I'd give this a bump since I've had (2) friends call me from the side of the road in the last week with this problem! :-X15
Every one of these trucks is prone to have this problem - fix yours BEFORE it fails!!!!!!!! :-X19 The key-in-ignition chime fix is a BONUS! :-jammin Which one of these is the right part for the boot thingy??????????? http://www.tousleyfordparts.com/part...component=Seal |
On my to do list,
Again, Thanks SkySkijason |
Just fixed mine thanks to this post! My wires were broke in half so it took a lil while to repair but I now have my od cancel switch back.:-jammin
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Thanks for the info!
This should be in the "Fix It" folder! HELLO! |
Originally Posted by jdw1
(Post 13042071)
This should be in the "Fix It" folder! HELLO!
Originally Posted by Stewart_H
(Post 11373725)
Creating all new tech folder thread to update the old one and add new information.
If you have a suggestion for an addition to this thread, please contact the Excursion forum moderator and it will be considered. Stewart Us moderators don't read every single thread ya know. In fact, that's why I have that above quoted statement in the tech folder! :-X22 :-jammin Next time, just drop a PM...sans sarcasm! ;) :D Stewart |
Bumping due to it happening to me!
Dang it, if I only saw this sooner! This very issue just occurred to me today (while filing up with fuel), and while I was stranded / sitting there with-out a clue what was going on (truck would run / start with no issue but no dashboard action or accelerator response).
Tow truck picked me up, and by the time we got to the dealer, I found the issue on this forum via my cell. I then was able to give a much better explanation to the tech regarding what to look for - unfortunately, they still have my truck since I'm relying on them to fix :-X18 |
Originally Posted by bflora
(Post 14179723)
Dang it, if I only saw this sooner! This very issue just occurred to me today (while filing up with fuel), and while I was stranded / sitting there with-out a clue what was going on (truck would run / start with no issue but no dashboard action or accelerator response). Tow truck picked me up, and by the time we got to the dealer, I found the issue on this forum via my cell. I then was able to give a much better explanation to the tech regarding what to look for - unfortunately, they still have my truck since I'm relying on them to fix :-X18
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My OD light came on several days ago, found this
http://imagizer.imageshack.us/v2/128...0/855/95sx.jpg Was only one wire but was almost all the way thru Cut that one and soldered back together and wrapped in elect tape |
Fuse #19
Do this fix before it happens....
Wife called me from town this weekend and said the Ex was dead. Cranked but no start and all the panel lights where out except the battery light. The computer read 0 miles to empty even though it had 1/2 tank. Apparently the overdrive had shorted out and blew a 10 Amp fuse #19 under the steering column. Amazing that a simple little fuse can bring the beast to its knees! Hopes this helps and thanks for the write-up. ssolid |
I'll be doing this to my truck real soon.
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Hey guys,
I was replacing fuses for my gauges and odometer dying and figured it was probably the short in the overdrive wire. However recently, the gauges all died and I went to change the fuse and it wasn't blown leading me to believe the short in the OD wires was completely through the wire. So then I changed he shift lever out and my gauges still aren't coming on, any ideas as to what I blew when my fuse didn't blow??? Any help is much appreciated! Thank you! |
Thank you for the redirect!
[QUOTE]https://cimg9.ibsrv.net/gimg/www.for...0c97bf4845.jpg
Diagnosis is spot on. This is definitely a design flaw. Thanks so much! A great find, and the price is perfect. I've looked for a replacement for.the whole harness, but by 2019 these things are hard to find, so I'm going in with the repair option. Curious about maybe just relocating that switch elsewhere (the dash) to get that wire harness away from the repetitive motion of the shifter. If so, I'll update. |
2002 Ex V10 with the same issue. The overdrive light would flicker sometimes, or say OD was off when it was on. I could slightly lift the shifter and the light would go off. Here's how bad mine was. Smooth wear right through the jacket. Don't wait if you have this problem! It only took 15 minutes. :-jammin
https://cimg2.ibsrv.net/gimg/www.for...392d996dba.png |
LIMP MODE
Just wondering if this would fix my problem with being stuck in one gear when I put the truck in drive maybe a short in the OD wires causing limp mode on transmission???
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Originally Posted by Donald Watson
(Post 19566108)
Just wondering if this would fix my problem with being stuck in one gear when I put the truck in drive maybe a short in the OD wires causing limp mode on transmission???
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Originally Posted by 2002Ex
(Post 19566097)
2002 Ex V10 with the same issue. The overdrive light would flicker sometimes, or say OD was off when it was on. I could slightly lift the shifter and the light would go off. Here's how bad mine was. Smooth wear right through the jacket. Don't wait if you have this problem! It only took 15 minutes. :-jammin
https://cimg2.ibsrv.net/gimg/www.for...392d996dba.png |
shift lever boot
Originally Posted by SkySkiJason
(Post 10816430)
Finally made time to fix this pesky little problem. I will echo the scores of X and Super Duty owners who have said repeatedly over the years to FIX this BEFORE the wires get chaffed enough to short... I didn't listen even though I knew about this when I bought the X and waited for it to fail :-X19.
The problem: The wires for OD switch travel thru the shift lever and after exiting they cross over the top of the column and plug into the wiring harness. Since these wires need to allow the shifter to move as well as the steering wheel to tilt - the wires also move when these things are moved. As the wires move back and forth this 1/4", they eventually wear thru the insulation and expose the wires. Initially, my OD lite would come on for no reason and eventually I was blowing fuses when shifting or using OD switch. As far as I can tell, THIS WILL HAPPEN TO EVERY ONE OF THESE TRUCKS - eventually. Seriously, its an EASY fix if ya do it NOW - it takes 20min, a phillips screwdriver and some tape! First, remove the (3) screws that hold the plastic trim around shifter. Unscrew the tilt steering lever and remove lower plastic piece. With ignition in 'on' position, press the little shiny ball on the bottom of key cylinder and remove the cylinder. Attachment 202621 Now you can slip the upper plastic over the shift lever and get it out of the way. Attachment 202622 Since I'm a dum redneck and waited until I had a problem, mine was worn completely thru one of the wires. I was trying to strip it back and repair it in place and pulled the other 2 wires apart where they were crimped at the hold-down thingy attached to this black trim piece. Attachment 202623 If I was smarter, I would have just unplugged the wire from harness and removed the pin in my hand and slipped the shifter lever, wire and black thing off so I could take the whole thing out where I could get to it... Don't try to slide that black piece off the shifter, its too big and will tear. This one was already torn and fugly - anyone got a part # for it?? I'd like to replace this one. |
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