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.

 

[DukeCanBuildit]

If the affected wires are an easily accessible short harness with a connector at each end, it might be economical to just get a new short harness. If it is too costly or part of a bigger harness that’s tough to remove and replace, finding a pigtail with enough wire to splice it into the harness is possible. Benny @LevittownFordParts.com is a great resource for this kind of thing. When rodents got to one of my wiring harnesses, he was able to determine the connector style and part numbers.

You’ll need to take some photos of the connector to help him out but whether you need a pigtail or a harness, he’s likely the go-to person for this.

Good luck!

 

[airline tech]

The Connector is part of the main engine harness assembly - no sub harness (Harness # 14290)

The Connector is replaceable via splices PN WPT-153 and in the wiring diagrams its connector # C350

5 -Wires
2 for bi direction motor power from the relays
VREF / Signal Return / and Signal

 

[COLMtnRanger]

Thanks to everyone-very helpful. One more question. If the connector needs to be replaced and the harness spliced, does anyone have a ball-park estimate of what a dealership would charge to repair? I'm considering an insurance claim. Thanks!

 

[DukeCanBuildit]

Thanks to everyone-very helpful. One more question. If the connector needs to be replaced and the harness spliced, does anyone have a ball-park estimate of what a dealership would charge to repair? I'm considering an insurance claim. Thanks!

Likely less than your deductible.

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