This article supersedes TSB 05-16-12 to update vehicle lines and model years.
Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used.
Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below.
IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY", ALWAYS TREAT AS A "WET" ENVIRONMENT.
Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness:
Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, position the connectors so they point downward, this will avoid the connector catching water in case of a water leak.
Figure 1 - Article 06-17-8
Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness:
Cut each wire from the extra connector as close to the connector as possible (Figure 2).
Figure 2 - Article 06-17-8
Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3).
Figure 3 - Article 06-17-8
Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4).
Figure 4 - Article 06-17-8
Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area.
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage