First I lost the power window functionality in the rear left door... didn't think too much of it, then I lost the power door lock functionality, which was bad because I was assuming my door was getting locked when it wasn't actually.


Pulled open my door this evening and found this:



Urk.


I think my truck overheard me when I was saying "I like a good electrical problem, those are my favourite."

I'll solder it up to get it working tonight, and then I'll see what a new harness costs... although really they should have used ultra-fine-strand wire with silicone insulation for an application that sees lots of flexing. My multimeter's test leads are such an example of wiring that is intended to see lots of flexing.

 

That looks like a good time. I've always enjoyed rewiring door hinge harnesses......
Is the harness the body or door side?

 

It's on the door side. The transition connector (C755) is in the B-pillar.

 

This will do until I can price out a replacement harness in the morning.

 

Looks pretty good Trent. Any idea on the cause or do you just use that door an awful lot?

 

I worked in the automotive field for over 20 years, 18+ as a Class A Dodge/Chrysler tech.

I have never seen a harness damaged like that from movement. Something cut those wires.

 

I have to agree with porthole, I am a certified master tech and doing this for 27 years, never seen them that bad mouse in the house

 

I'd have to agree. This harness hasn't changed since the Super Duty was introduced. You don't see a large number of issues with the older trucks - I suspect something else caused the failure.

 

Kind of what I was getting at with my question...something isn't right here

 

Hi guys, I would almost agree with the cut theory going on here but then.
I noticed that the wires are (cut) on opposite sides and some additional cracking of wire jacket.
Lets not forget how long and cold last winter was ??
Looks like the rest of us are from south of Trent !
I had similar issue with a 20yr old livestock trailer harness last winter.
the harness never cracked before in the cold.
Except this time it was -20F when I went to plug it in !!
Nice post Trent thanks for sharing !!

 

That's an excellent point Tim...

 

Hey Andre, I don't know for sure, but that's my story and I'm stickin to it !!
Lol !!

 

I couldn't find any other debris in the rubber flex that might cut into it. In fact that flex conduit was very clean other than copper wire strands. It is also taped off on the door side, and the other end terminates right into the connector - there is no opening for rodents or insects to enter.
I've seen cracked insulation before on wiring that gets exposed to cold, remember we see -41°C for at least a week during the winter time.

That's what I was getting to with the wiring insulation... it looks like thermoplastic insulation like THHN as opposed to thermoset insulation like what you would find on SOOW cable. I wire lightbars and stuff with SOOW cable because of its low temperature rating. Same as the stuff I used on my in-bed power outlet. Even then at -40 SOOW cable is quite rigid and I try not to flex it too much, whereas your regular extension cord SJTW cable literally just cracks in half.

Anyway, I ordered a new harness, complete assembly with all connectors, tree clip retainers, and the flex came out to $59 which isn't cheap but to put it into perspective I would have spent more than that on my time and materials to completely redo the one I've got. The dealership service department has seen lots of these, typically the usual cause of complaints involving loss of power windows, power mirrors, no sound out of the door speaker - but on the drivers' door as that is typically the most often used.

I'll take a look when I get it (expected tomorrow) and see if I need to reinforce the wiring within the flexible duct with cloth/gaffer tape or something.

 

Trent, if your like me I open the drivers rear almost as much as the front due to the fact I throw some thing in, and take something out of there every time I get in the truck.
I would assume the reason the front harness hasn't given trouble, yet is the additional room available up there for the harness.

 

Project for this long weekend.