Oem Connector Repair Procedures Ford Econoline E250

Troubleshooting wiring harness and connector hidden concerns

The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration.

Non Safety Restraint System Repairs

Several components, such as PCM and ABS modules, may utilize gold plated terminals in their connections to the wiring harness. Replace all gold plated terminals with either a gold plated terminal or a "universal" service kit with a plating of silver or tin with grease already applied.

Restraint system terminals must not be removed or repaired

Restraint terminals are not to be repaired/replaced with individual pins/terminals.

Ford no longer requires replacement of the affected harness if a restraint connector or terminal requires service. Wiring Pigtail Kits designed specifically for the deployable components (for example, Airbags or Seatbelt Pretensioners) of the restraint harness should be used. Available Wiring Pigtail Kits can be identified in the wiring connector face view.

Scheme 593

Check for unlocked terminals by pulling each wire at the end of the connector.

Scheme 594

Scheme 595

Lock may be displaced into an unlocked position; pull on the connector to verify the lock.

Scheme 596

Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.

Scheme 597

Scheme 598

Scheme 599

Remove the tape and flex/feel each circuit for a reduction in diameter at break.

Recommended splicing method - Solder (For 16 AWG/1.0mm and Smaller Diameter Wire Only)

Note. Cut and splice one circuit at a time noting the original wire to connector pin locations. This will avoid miss-connections.

Scheme 600

Scheme 601

Scheme 602

Scheme 603

1. Disconnect battery ground cable.
2. Strip wires to appropriate length.
3. Install heat shrink tubing.
4. Twist wires together.
5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 AWG/0.5-1.0mm) or ES-2 (10-18 AWG/0.8-5.0mm) to seal wire splice.
6. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires.
7. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. NOTE: On smaller wires, use pliers to gently squeeze the ends of the heat shrink sleeve (while heat shrink is still warm) to ensure a tight fit and close any air gaps
8. Reconnect battery ground cable.

Recommended splicing method - Crimp (For 10-22 AWG (0.35-5.0mm) Diameter Wire to Like Wire Diameter)

Note. Cut and splice one circuit at a time noting the original wire to connector pin locations. This will avoid miss-connections.

Scheme 604

Scheme 605

Scheme 606

Scheme 607

1. Disconnect battery ground cable.
2. Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands.
3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-26 AWG/0.13-1.0mm) or ES-2 (10-18 AWG/0.75-5.0mm) to seal wire splice.
4. Select appropriate wire splice for the wires to be spliced.
5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
6. Center one end of the wire splice in the appropriate crimping chamber.
7. If visible, be sure to place the brazed seam toward the indenter.
8. Insert stripped wire into the barrel.
9. Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice. NOTE: It is recommended to apply solder at the ends of the barrel.
11. Check for acceptable crimp. Crimp should be centered on each end of the butt splice. Wire insulation does not enter butt splice. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair.
13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing.
14. Reconnect battery ground cable.

Scheme 608

This chart is to be used when pigtails or terminals are of different wire gauge than the vehicle harness.

Scheme 609

Note. If joining a smaller diameter vehicle wire size to a larger diameter pigtail, it is acceptable to cut strands from the pigtail to fit a barrel splice if necessary.