after all the work i have done to my 04' f250 6.0 i found a tiny leak today that has been driving me nuts trying to find it. all fixed now. when i was trying to locate the leak i noticed several of the wires right at different sensor plugs have a bare wire like the insulation had eroded off the wiring. is this common? I'm gonna take a day and dab some liquid tape on the bare wires just so they don't corrode away. do they sell a replacement harness for the injector and sensors? also found a few sensor plugs broke were they won't seal. like have the out portion of the plug has cracked and broke.

 

Alliant Power carrys a lot of our replacement injector parts and sensors and plug-ins.

 

Use something like a BWD CT899 or CT898 connector though. Don't just butt connect it in.

 

True I preferr soldering to anytype crimp connector,but I been doing soldering connections for so long I sometimes forget to mention it. Guess I take for granted that everybody solders in. LOL

 

That's why I like those connectors. They crimp, Have solder inside as well as glue to hold the wires and heat shrink. Once they cool off they are stronger than the wire and water tight. Cost a little more but its easier than heat shrink and solder is.

 

There is some good reasoning behind not soldering wires.

It has to do with the lack of flexibility and work hardening
of the wires. Where with crimping you still have individual
strands that can still flex to the crimp point.

But we could do a whole class on the subject and not even
start to cover things just in the automotive world let along
all the other uses. AND There are times where soldering will
be the better method.

DieselTechRon has a guy that he works with that has been able
to get a lot of the oddball connectors and at a good price from
what he has been saying.

You might want to send him a question and get the link to the guy.

DieselTechRon - Serving the Ford Diesel Community

Sean

 

I prefer to solder as well but these short wires need the flex in it like was mentioned so will do the crimp connect. nothing like replacing a connection and have a slight pull on the wire because the solder won't flex then ending up changing it again later cause the connection broke again. a couple that i found only have about 3/4" outside the harness loom and would be tight either way unless i pulled them completely out of the loom and did it but just doesn't seem feasible to tear the whole loom apart.

 

On some of the short locations you can unwrap and
get more wirer to work with.

One thing I really like it the mastic lined heat-shrink.
You cat a water proof seal that way.


Sean

 

just have to figure out what all plugs i need then go from there. i figure some of the splices will be in the loom and should gain a little length but cutting close to the plug hoping the new plug has a good length of lead.