Cheap copper being used by Ford???
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Hotshot
Joined: Jul 2013
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Cheap copper being used by Ford???
Well let me start by saying last winter I had a battery check light that wouldn’t go away in spite of the batteries being good. Ultimately the problem was corrosion (green powder) on a copper wire in the harness on the pax side of the engine. The wire disintegrated from within and the plastic insulation showed no signs of a problem. When I understood what had happened, I said wow, are we in for more of these gremlins in the future.
today I saw this video and it reminded me of this copper wire corrosion problem. I’m sure you will find it interesting....take note of the state of the copper in the wires in question.
today I saw this video and it reminded me of this copper wire corrosion problem. I’m sure you will find it interesting....take note of the state of the copper in the wires in question.
Post Fiend
Joined: Nov 2001
Posts: 6,748
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From: Tallassee, ALabama
The corrosion is typical of copper cables and sulfuric acid. We often do not clean the battery terminals and then spray or coat the cables and terminals with an acid neutralizer.
Ford does make/sell a positive or negative crimp on battery cable end to replace the corroded ends.
Ford does make/sell a positive or negative crimp on battery cable end to replace the corroded ends.
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Hotshot
Joined: Jul 2013
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This is not sulfuric acid corrosion.
due to no seals around the wires and end connectors...copper is exposed and since it is not oxygen free copper..it corrodes leaving the plastic insulation intact.
note that there is no break in the insulation and the abundance of green copper powder.
oxygen free copper and simple rubber seals on end connectors would prevent this....but that would cost a few pennies per connector.
due to no seals around the wires and end connectors...copper is exposed and since it is not oxygen free copper..it corrodes leaving the plastic insulation intact.
note that there is no break in the insulation and the abundance of green copper powder.
oxygen free copper and simple rubber seals on end connectors would prevent this....but that would cost a few pennies per connector.
Hotshot
Joined: Oct 2006
Posts: 10,174
Likes: 8,042
From: Texas
Nothing new. And not Ford only.
Way back in the early 1970’s I had a Chevrolet company truck that corroded a fusible link inside the insulation. Mechanics had a hell of a time figuring it out. 2010 Jeep I had did battery cable the same way.
Way back in the early 1970’s I had a Chevrolet company truck that corroded a fusible link inside the insulation. Mechanics had a hell of a time figuring it out. 2010 Jeep I had did battery cable the same way.
Cargo Master
Joined: May 2012
Posts: 2,616
Likes: 1,190
From: Door Cty/Florida
I've always sprayed my battery terminals and down the wire with the red battery terminal fluid. First thing I would do on a new truck. This is not a new issue.
Does this help at all or will the wire corrode anyway and I was just wasting $5 on a can of spray?
Bruce
Does this help at all or will the wire corrode anyway and I was just wasting $5 on a can of spray?
Bruce
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More Turbo
Joined: Dec 2011
Posts: 572
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Looks like road salt invaded the wire where it goes into the plastic housing. I have seen road salt corrosion in trailer wiring that traveled inside the insulation for several feet. In the video the tech had discolored copper because he didn't cut enough away and chose to crimp on the corroded copper. Then he added a shielding that formed a nice funnel to speed the salt invasion The customer will be back in a year or two..
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