Fulltext TSBs

Technical Service Bulletins

TSB
05-16-12
  • SERVICE WIRING HARNESS REPLACEMENT GUIDELINES – SERVICE TIPS
Publication Date: August 9, 2005

FORD:
2000-2003 Focus
2005-2006 Focus, Mustang
2002 Ranger
2004-2006 F-150, Freestar
2005 Escape
2005-2006 Expedition
2006 F-650, F-750
LINCOLN:
2005-2006 Navigator
2006 Mark LT
MERCURY:
2004-2006 Monterey
2005 Mariner

This article supersedes TSB 04-14-7 to update vehicle lines and model years.

ISSUE:

Ford Motor Company has “consolidated” high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used.

ACTION:

Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below.

SERVICE PROCEDURE

NOTE:IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE “WET” OR “DRY”, ALWAYS TREAT AS A “WET” ENVIRONMENT.

Extra Open Connectors – Procedure For “Dry” Environment/Interior Wiring Harness:

Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, position the connectors so they point downward, this will avoid the connector catching water in case of a water leak.


Figure 1 – Article 05-16-12

Extra Open Connectors – Procedure For “Wet” Environment/Exterior Wiring Harness:

  1. Cut each wire from the extra connector as close to the connector as possible (Figure 2).


    Figure 2 – Article 05-16-12

  2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3).


    Figure 3 – Article 05-16-12

  3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4).


    Figure 4 – Article 05-16-12

  4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area.

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage