Here is a link to the fuse locations of the CJB. http://www.revbase.com/BBBMotor/Wd/DownloadPdf?id=73228

If your Excursion is like my 02 Excursion, the fuse numbering on the fuse box cover doesn't match the diagrams. You can use the above link to find which fuse is f2.22

 

Ok, think we've found it. Power to the relay, power to the fuse, power to the first half(male side) of the 42 connector. Power disappeared on the other end of the female side. The wire in question is pin 24. Opened up the harness to isolate the red wire, as I was checking it our on the female connector, the wire fell out of the 42 pin connector.

So to my next question, how is the blazes do I address that!? lol Thanks again.

 

I'm assuming the wire did not have the pin still connected.
1. bypass the 42 pin connector by splicing in a section of wire to the 2 wires going to pin 24 and use a quick disconnect in that wire so you can pull it apart when you need to pull the 42 pin apart. http://www.ebay.com/itm/200-PK-22-18...-/222222553101 or like this http://www.ebay.com/itm/50-Heat-Shri...-/351965400376 just get one for your wire size
2. You can buy a whole new harness
3. Di-assemble the 42 pin connector and remove the old pin and solder it back to the wire.

4. Find the replacement pin that goes in the 42, remove the old pin and discard, strip the broken wire back to make sure there is no corrosion which may be why the wire broke in the first place, crimp/solder the new pin on. Don't forget to pull some slack out of the harness for the wire your working on because it will be slightly shorter than all the others. if you don't get some slack there will constant tension on that wire trying to pull it back out, eventually the pin lock or the wire will give up.


Personally I would do nbr 4

 

Save yourself the Heartburn, at that mileage, Replace them both, you're gonna have to eventually anyway. just say'in

 

The Ex forum tech folder sticky thread has links to Ford pdf's for owners manuals which include the fuse locations and identifiers.

Stewart

 

Yes Stewart. That is a great resource, but this is what causes the confusion. The labeling of the fuses is different between the owner's manuals and wiring diagrams. I was very confused the first time I started trying to find the fuses labeled in the wiring diagrams. You can see the difference in the pictures.

 

A new harness (if you can get one) is about $1000 (maybe from International?). A used harness in good shape will go for $400-600 when I have looked.

 

It runs! Thanks a million Erik. Ran a jumper wire, bypassing the 42 pin. For anyone else it's pin #24 that was my problem. All codes cleared, running great.

 

Good work! Way to stick with it and save yourself hundreds of dollars!

 

GOOD JOB btw on finding your problem. If you want to do a quick repair and get it going for now, you can take a short piece of wire (same gauge or thicker) and use a connector to add it to the corresponding wire on both sides to jump across the 42 pin connector.

I have a device that connects to 1 end of the suspected wire that creates a signal passing through the wire. I use the receiver to scan across the wire loom until I lose the signal. It does not work all the time, but I have found a lot of broken wires inside a closed loom this way.

 

I must have been making my last post when you posted that you already jumped it. You deserve to give yourself a pat on the back because electrical issues stump a lot of really good mechanics.

 

And they charge you for all those hours after they didn't fix it anyway...

 

Erik, I'm not sure I understand what you're saying. Are you saying the owners manual is wrong and the wiring schematic is correct? Or are you just pointing out there is a difference between what Ford shows in the owners manual versus the wiring schematic?

Stewart

 

I don't know how to answer which is wrong. But if somebody was looking at a fuse in the wiring diagram and looked at the owner's manual to find it's location, they would not be able to find it. That is why I have to let people know there is a difference and they just have to match the location of the fuse in the panel.

The first picture is from the Owner's manual pdf from the tech folder.

The 2nd picture I posted is from the wiring diagram schematics in the tech folder (btw, I use alldata diagrams and they correspond with the tech folder).

All the wiring diagrams that I have looked at in the tech folder and Alldata refer to the fuse labeling in second picture.

Example: If the wiring diagram said F2.49, the owner's manual labels this fuse 101.

I guess the most accurate statement would be that if the wiring diagram being used labels the fuses and relays as simple numbers 1 to ??, than the owner's manual is correct. If using diagrams that the fuses and relays start with a letter followed by numbers, than they have to refer to the second picture.

On my Excursion, the black plastic cover over the fuse panel is labeled with simple numbers (agreeing with the owner's manual)

 

But you certainly know how to clarify very well!

Stewart