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I figured I'd go ahead and close this one out. I'm 98% sure I've found the cause of my "No Crank" woes. I have been living w/ the no crank ever for close to 2 weeks now, most of this week was lost to rain, and found an opportunity to get back under the truck for another look at that range sensor plug. Got it apart and the sensor side of the connector was soaked. I could see the remnants of the dielectric grease I'd packed it with last fall, but obviously it wasn't doing it's job any more. Hosed it down with isopropyl then some low pressure shop air. Hooked it back up and hit the key with success. So now I'm researching some more extensive waterproofing methods for a long term/permanent seal.
The weatherseal in that connector should be able to handle normal splashing unless it is in bad shape. I don't know if you can buy the weatherseal on its own but the pigtail isn't very expensive.
How about where the wires go through the connector? I’d try sealing the inside with dielectric grease and the wires with silicone. If that’s doesn’t work, I’d then change the pigtail. I prefer unspliced wires when possible.
I replaced the connector and range sensor last fall when I lost 3rd and 4th after a fluid and filter change. Ended up finding a folded over main valve body gasket and a good bit of clutch dust. Likely stirred up from me draining the TC.
Normal splashing is a luxury my truck is unfamiliar with. She's "Oilfield Trash", If its's not covered in mud and crude oil, and seasoned with saltwater, she's not interested.
I did find a write up on Pirate though that explained a technique where after cleaning and filling w/ dielectric, a wrap of electric tape was put over the locking tab on any connector. Then a single strand of thin wire put over that. Then the whole thing was coated with liquid electric tape. The idea was that when you inevitably have to undo the connector, you could simply remove the wire to break the seal. Then pull the tape exposing the lock tab that should be clean and dry. Not sold just yet but may experiment on some old plugs or something for a proof of concept.
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