I've got a set of Infinity Kappa 572.5cf's (5x7 2-way w/crossovers) in my truck. Lately, the front left speaker has been cutting out the lows, the tweeter will play, but the woofer won't. If I turn up the volume, the woofer will start playing again.

At first I thought it was because I'm running them off the stock HU and it's not putting out enough power...but they've worked fine at all volumes for almost a year now. I pulled the door panel to check it and I noticed two things.

First, the door "rod" mechanisim was pinching the wires from the crossover to the tweeter when the door is open. The wires weren't cut or broken, just kinked. I zip-tied them up out of the way.

Second, the "rod" was bumping up against the crossover when the door is closed. The crossover is mounted inside the door with double sided sticky tape, and I put a dab of silicone where the wires enter & exit just incase a bit of water gets down in the door. The "rod" was just scraping up against it; the crossover case had a scratch and a small gouge in the plastic. I grabbed hold of the crossover and the woofer started working again, so I thought it was just the "rod" bumping it. I repositioned the crossover and buttoned up the door.

Everything was ok for two days, and then it started cutting out again. If I bang on the door, the woofer will come alive again. Could the crossover had been damaged by the "rod" that severly? Why would the woofer work only when I turn up the volume? Any insight into this funky problem will be greatly appreciated!

 

Even though the wires are just kinked on the outside. they may still be cut on the inside. You may want to cut out the kinked areas and reattach the good wire. Wrap the area where it may hit with some electrical tape so the wires wont get kinked again. Also you may want to check out the connections to the soeakers. If one of them is loose, it may be losing the connection from the terminal for just a fraction of a second and that will cause it to cut out.