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Decaying wiring harness
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Senior User
Joined: Mar 2010
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From: Kearns, UT
Decaying wiring harness
So....last weekend, I used my truck like usual. Monday afternoon, as I was heading to work, my truck would crank, but not start. First time this ever happened. I looked as various things, like verify I had low oil pressure, verify I was getting fuel to the secondary fuel filter, couldn't find any blown fuses. Since I don't have a way to retrieve codes, I had a dealer I am comfortable with diagnose it. They say I have a wiring harness that is decaying and needs to replaced. I was at work when I took the call and should've asked a few more questions before I hung up. So I'm not sure exactly which harness it is. I'm going to call back in the morning for more exact information on which harness. First they quoted me $1100 for the harness and $600+ for labor, but later quoted me $1070 for both harness and labor after I balked about the price. I am super busy at work with only 1 day a week off and am leaning towards letting them fix it. But how common is this kind of problem? Does the price sound reasonable? Thanks for your help.
Kurt
Kurt
Fleet Owner
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
The last injector harness I got was a bit over $200. And when I was checking on that I also asked about
the main harness and that was in the $800 range. Both are fairly straight forward jobs and the only tight
spots are the Can crank and A/C clutch connectors. So if your not worried about a little skin and dirt under
the nails I would say tackle it yourself. Wgeb doing the injector harness there are 2 intake bolts that need
swapped. Your taking a little stress off the harness by exchanging the place of a bolt for the stud next to it.
Not more than a 6-pack worth of beer in the amount of time needed to do the job.
the main harness and that was in the $800 range. Both are fairly straight forward jobs and the only tight
spots are the Can crank and A/C clutch connectors. So if your not worried about a little skin and dirt under
the nails I would say tackle it yourself. Wgeb doing the injector harness there are 2 intake bolts that need
swapped. Your taking a little stress off the harness by exchanging the place of a bolt for the stud next to it.
Not more than a 6-pack worth of beer in the amount of time needed to do the job.
Fleet Mechanic
Joined: Nov 2008
Posts: 1,443
Likes: 9
From: South Alabama
It’s not real commond, but as our trucks age it will get more so. As Sean stated it’s not really hard, just a little time. BUT it might be the issue and it might not. You may only have a loose connection. A good code and DTC monitor would help you out and and save $$$. ForScan and Torque Pro (for smart phones and tablets) can be had for $5.00 (there is a free version of ForScan for Windows laptop)and an ELM327 connector off Amazon for $20.00 can save you a lot of headaces and dollars. Even if you let them do this I would get a monitor. Good luck.
Hotshot
Joined: Dec 2014
Posts: 17,828
Likes: 3,113
From: Jersey Shore
As stated the main harness is not inexpensive by any means, and loose connectors, especially FICM clips, can over time become an issue. The 6.0L harness lay certainly has caused issues for a good amount of people, either by bolt contact or internal to the harness shorting of a wire with the ground shield wire cutting through insulation. So if the service personnel are good they may have identified an issue, something that has perplexed others to a great cost to owners. When I pulled my harness which was installed as a replacement in 2010 I found some locations where bolt head contacts were worrisome.
And yeah, 6.0 owners need monitoring equipment.
Sean, you brought up a good point about the injector harness, do you have the fastener locations to add for the thread?
And yeah, 6.0 owners need monitoring equipment.
Sean, you brought up a good point about the injector harness, do you have the fastener locations to add for the thread?
Token Redneck
Joined: Jun 2007
Posts: 9,337
Likes: 346
From: Breckenridge, TX
So if he got quoted roughly his parts cost for the work.... I'd let the dealer do it. Pays within $100 of the same amount either way, getting the truck running while he's making money at his job might not be a bad trade-off.
Fleet Owner
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
As stated the main harness is not inexpensive by any means, and loose connectors, especially FICM clips, can over time become an issue. The 6.0L harness lay certainly has caused issues for a good amount of people, either by bolt contact or internal to the harness shorting of a wire with the ground shield wire cutting through insulation. So if the service personnel are good they may have identified an issue, something that has perplexed others to a great cost to owners. When I pulled my harness which was installed as a replacement in 2010 I found some locations where bolt head contacts were worrisome.
And yeah, 6.0 owners need monitoring equipment.
Sean, you brought up a good point about the injector harness, do you have the fastener locations to add for the thread?
And yeah, 6.0 owners need monitoring equipment.
Sean, you brought up a good point about the injector harness, do you have the fastener locations to add for the thread?
Hotshot
Joined: Dec 2014
Posts: 17,828
Likes: 3,113
From: Jersey Shore
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Fleet Mechanic
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Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
The tape I got off Amazon for about $4 per roll. I used three rolls.
I had some working room. I wasn’t about to put that ratty harness back in this pretty engine bay!
Wrap from the connectors inward and zip tie if you have to leave an end exposed so it won’t be able to start unravelling.
Engine harness done!
I got a new engine and injector harness last month from Tasca Ford for about $565 (mine is a 2003 so the ICP plug is on the branch with the IPR) and replaced both in one day. The hardest part was disconnecting and reconnecting the crank sensor. I cut the end off and routed it in front of the A/C compressor. The factory routing is ridiculous! To get it back where it was you have to remove the compressor which is just not worth it.
I test fit both harnesses and moved some of the clips and fasteners where they really needed to be to work right. I then wrapped both harnesses with Tesa heat resistant harness tape then installed them.
Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
Here’s the link for those harnesses. I see the OP has an ‘04 so if his ICP is in the back this is the harness kit that will work.
https://www.tascaparts.com/oem-parts...t-3c3z12b637ab
https://www.tascaparts.com/oem-parts...t-3c3z12b637ab
Fleet Owner
Joined: Nov 2003
Posts: 27,900
Likes: 3,617
Don't forget, 04's had a change in December of 2003 (several months after the ICP sensor move) where the GPCM was re-oriented and it takes a different harness than the ones between Sept 29, 2003 and Dec, 2003 (don't recall the specific day of the month).
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