Wires Going Into Transfer Case Connector Broken

[COLMtnRanger]

I was on a gravel road and heard something hit bottom of truck. Immediately got TMS Fault and 4x4 Fault. When I investigated, two wires going into transfer case connector were broken. I assume they were hit by a rock flying up. Questions: 1) Can the wires be simply spliced? 2) Can that connector be ordered so there is a longer length of wire to splice? 3) Hoping I don't have to replace the entire cable harness? Thanks!

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[RangerBill]

I was on a gravel road and heard something hit bottom of truck. Immediately got TMS Fault and 4x4 Fault. When I investigated, two wires going into transfer case connector were broken. I assume they were hit by a rock flying up. Questions: 1) Can the wires be simply spliced? 2) Can that connector be ordered so there is a longer length of wire to splice? 3) Hoping I don't have to replace the entire cable harness? Thanks!

If the wires are not broken right at the connector, you should be able to splice them. You should make sure that the splices are waterproof.

 

[ScarzRanger21(2.0)]

Honestly, I’d recommend just replacing the harness. Couple reasons for this.
1) Every splice you put in a wire is a potential failure point down the road. Especially on a vehicle where things are moving and shaking around all the time.

2) The wire wasn’t cut, it was ripped apart from a rock or a stick. That means it was pulled tight enough to stretch and tear. There’s no telling if the wire is damaged somewhere else in the harness that you can’t see.

The electrician in me says play it safe and just replace the harness. Maybe splice it for now to get by but I would plan on doing it right when you can.

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