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Proper Method to Reinsert a Wire Pulled from Connector
The previous owner of my '01 Excursion had a tire blow out that damaged the wiring harness on the driver's side. I have had a P0705 code since I purchased it. I found a white/black wire that has been pulled out from the connector (see below). What is the proper method to secure this wire back into the connector?
Usually there is a special tool to slip over the pin in the connector and pull it out by the wire. You may have to take the connector apart some, especially since you don't have a wire connected to pull it out with. Unless you have a new pin and special crimpers, you may be able to open the old pin up in the back and solder the wire back in place.
I've worked quite a bit on Ford connectors and would advise removing the black connector and find the pin for that wire still attached to its mating pin inside the other half of the wiring harness connector that would remain behind. Be careful to not compress or mash the pin's locking tab, those that hold the pin inside its connector shell. Using small tools open the wire crimping area, re-insert the wire and carefully close the tabs around the wire. I would suggesting soldering that wire to the pin BUT be careful to not use too much solder making re-inserting the pin back into its shell.
There may be a few YouTube videos showing how others do this---give that site a look.
The DTC you cite points to the Transmission Range Sensor---are you have problems in that area?
Thanks for the advice. I will try to disassemble the connector and try to retrieve the pin. Fortunatley I grabbed a wiring harness from the junkyard last time I was there so I have a donor connector to play with. My original intent was to just swap out the harness, but I learned quickly that is a MAJOR job. In fact, I had to do some cutting just to get the junkyard harness out.
My other issue is that the connector itself got damaged. It snaps together, but is not hermetically sealed any more. I will need to figure out a way to shrink wrap/tape that after I have confirmed all of my connections are good.
Yes, the P0705 code is for transmission range sensor. Luckily the EX drives and shifts perfectly. I still want to get it fixed though. I will report back with any progress to share.
Most connectors have an o-ring type seal used to keep moisture etc away from the actual terminals. There might be a small seal placed on the wire to further keep moisture from entering the "joint". Using a small dab of dielectric grease on the inside of the connector where it mates against its other half is a good way to keep the contacts as dry as possible.
I found an outstanding video of how Ford electrical connectors work by @FordTechMakuloco. This guy is a godsend. His Ford videos are a blessing to humanity!
Using that video I was able to determine that my connector is missing the orange plastic insert. Luckily I have one from the junyard harness I had on hand. I was able to remove the wiring terminal pin and now I am on the search for a part number for a replacement. Does anybody have a Ford, Dorman, or other part number for this (shown below)?I'd prefer to avoid trying to decrimp and recrimp that one. It needs to be hollow to accept the male pin on the other connector and it needs to have the narrow section to allow the internal clip to hold it in place.
In the process I also realized how broken my plastic connector really is. Here is a pic of the pin almost pushed fully out.
I also found some other pins that probably weren't making a good connection and need to be reseated at a minimum.
Generally the entire AuVeCo catalog is another great source of parts like this. It's rather extensive but with a little digging you'll find something of use: https://www.auveco.com/solderless-terminals
Thank you @JWA. That first website provided me with the Ford part number, which is E7EB-14487-AA. I called a local Ford dealership and they said that part was 'obsolete'. They probably just didn't want to hassle selling one since they are very cheap. The chain auto parts stores don't have them either. Instead of ordering one off the internet I just cut the same wire off the donor harness to create a pigtail with that connector on the other end that I could splice together using a combo crimp/shrinkwrap/solder connector.
Connecting that wire and pushing all the pins back into place to get a good connection with the other wires on the damaged connector fixed all the check engine codes! I still need to drive it and check it for deeper codes with ForSCAN, but I'm pretty sure it fixed everything. When I get some time during warmer weather I may just bite the bullet and remove all the wires and swap out the good donor connector because the only way both ends will stay connected right now is with a zip tie compressing them. I'll probably order some of the terminals also just to have them on hand in the future since they are cheap.
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