Well, after further searching for issues with my harness, I discovered a few problem areas that are going to need attention. The first issue was the two wires going to the sensor for the CAC temp were bare and touching together which threw a code. Got that temporarily fixed and need to buy a repair harness/connector. Still was having hard starts like the glow plugs weren't completely doing their job, so I decided to ohm the glow plugs from the GPCM to the glow plugs so that I could validate the complete system all the way back to the module. All circuits were at .2-.4 ohms. If I'm correct, the less resistance the hotter the plug should be since it is more or less a dead short that makes the plug hot. Well, low and behold, upon inspecting the terminals in both of the connectors I found that the terminal that provides 12 volts to the driver side glow plugs had evidently lost it's tension and overheated not to the point of destroying the connector, but just barely, and I mean just barely as I had to examine it very closely to even notice that a very small portion of the connector had melted almost to the extent of a light layer of paint. I could visually see that the terminal was sprung wider than the other terminal for the passenger side connector. Now the big question is this terminal even available to repair this connector since there is basically no damage to the connector cavity? Any help would be appreciated as I have already searched this site and found nothing pertaining to this subject. I don't really want splices on all of the wires going to the GPCM. Thanks in advance.

 

are you sure you are seeing .2-.4 ohms to the injectors? new glow plugs are generally 0.6/0.7 ohms. the numbers get higher as they age.

I was thinking you were talking about the connectors to the UVCH but sounds like you are talking about at the GPCM? can you post a pic? you can get any terminal made, just need to know what it looks like.
Is you GPCM still good? I recently watched a video where a wire heated up and showed on the GPCM but the GPCM actually failed.

I don't have a GPCM as I have a non cali SD, so I do not know what you need exactly. If I knew I could help you find what you need

you definitely don't want to buy GPCM repair pigtails I can't see what kind of terminals they use or if it's even accessible...Giving this is what you are talking about
if this is what you are actually talking about, I imagine you will need something along the lines of these

 

Excursion or CA emission Superduty main wiring harness will be pn YC3Z12B637EA

 

I just reread the OP. if it has terminals, it should be fairly easy to tighten the connection of the terminal using a pick tool or tiny screwdriver. If you take apart the connector, then it would be easier

 

I did tighten the terminal already. When a terminal has been hot, it loses its tension. It actually cranked better this morning, but it’s just a matter of time before the terminal’s grip will give up the chase again possibly doing damage to the connector cavity. Hopefully, this terminal I need is generic and used in other applications. I’m thinking I’ll call Ford and see if they know the connector part # which will narrow down my search for the terminal that fits in the connector cavity. I looked all through the connector section on this site and didn’t see a connector that looked like the two that connect to the GPCM.

 

I have replaced a few GPCM pigtails for exactly this reason. I used an International-branded repair kit that includes non-insulated butt connectors and really, really good shrink tubing.

I prefer to remove harness from the truck so the splices can be properly staggered. This is also a good opportunity to clean and inspect the harness and repair loose tape and damaged wire loom.

 

I've recently discovered these kind of connectors:


https://www.fcpeuro.com/products/bmw...r-61138353747?

They are designed to replace butt connectors for an inline splice. They grip insulation and wire like OEM wedgelock/metripak terminals.

Just don't forget your heat shrink.

 

Some of you might disagree with me, but this morning I had the good fortune of finding the OEM main engine harness from a Ford dealer in Ohio kind of by mistake. I called a local dealer trying to explain the terminal and the connector in which it is used. I previously had made the comment that I had entertained the thought of replacing the whole harness as it is getting weak and worn, but the harness was obsolete. Without me asking him to locate the harness, he actually found a brand new FORD OEM YC3Z12B637BA harness! Gave me a great price too! I will report back once it is installed to let you guys know if this cures all of my issues. Thanks for all of your replies and help.

 

yeah, for the price of just the GPCM repair kit, an entire harness is only $400-500 more.

 

I like OEM if possible.
if not,

consider these folks:Swag Performance in TN

https://tinyurl.com/5eaem59t with California Emissions $250.00 new
you need to search for you year/model truck
https://swagperformanceparts.com/eng...uto-w-o-calif/

 

I had already bought a repair pigtail for the manifold air temp, which I’m going to return. It was $42.00 from NAPA. If I had purchased the two GPCM pigtails, by the time they were shipped to me, that would probably been another $100.00 or so. Then there is the labor involved by me to repair the harness which is the only part that is free. I didn’t mind splicing anything that just involves 12 volts, but when parts of the 5 volt reference system are breaking down also it is worrisome as to how much longer the harness was going to last. I figure I’m way ahead once this harness is installed.

 

There it is! Come Saturday it will be installed.

 

I fixed my harness because it was ‘economical’. Fast forward a decade and now I’m thinking I should get a new one ‘while I can’.

 

I have been wondering the same thing,
as of now, no issues,

but in 5 years? or 10, will it be needed?
but in 10 years, I will be 90 and maybe not driving anymore

 

We won't be able to buy fuel for these in a couple years (or sooner) anyway.

If fuel's still available, the next step is outlawing anything that burns it anyway and making it extremely cost-prohibitive.

I'm working on my bread line stance (like yoga only less excercis-ey) in preparation.