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  #11  
Old 07-25-2022 | 11:03 AM
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Flounderguy
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Just something to think about. My 95 5.2 lost power seven months ago. It died at idle, surged, bucked, and sounded horrible. I chased everything, threw a lot of parts at it, gave up and took it to a shop. Many dollars later, it ran well, for about a week. Then the same symptoms came back. I had codes, off and on, for sensors and injectors. I finally realized that moving the wiring harness would cause problems to appear and disappear. Hopefully, in the next couple days, I will have finished replacing about 200 ft of wiring in the harness. I think the 27 year old wiring is brittle and breaks when the harness it moved around. All I have left to do is to replace fifteen or so splices into the 60 pin PCM connector with new pins. I am waiting on the pins. I tested it and it runs great with the new wiring.

I replaced the ASD output that feeds the injectors, alternator, coil, ASD and O2 sensor. I replaced the sensor ground circuit that feeds the intake air temp sensor, ECT, crank pos, cam pos, VSS, TPS, and MAP sensors. I also replaced all the injector driver wires, the sensor signal wires, and the 5 volt supply wiring to the sensors.

If I get the PCM connector pins and hook them up, and put the harness back in, and the truck still has problems, there will be a lot of cursing in my garage.
 
The following 2 users liked this post by Flounderguy:
SRAC76 (07-25-2022), tndakman (07-25-2022)
  #12  
Old 07-25-2022 | 04:36 PM
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bronze
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Originally Posted by Flounderguy
Just something to think about. My 95 5.2 lost power seven months ago. It died at idle, surged, bucked, and sounded horrible. I chased everything, threw a lot of parts at it, gave up and took it to a shop. Many dollars later, it ran well, for about a week. Then the same symptoms came back. I had codes, off and on, for sensors and injectors. I finally realized that moving the wiring harness would cause problems to appear and disappear. Hopefully, in the next couple days, I will have finished replacing about 200 ft of wiring in the harness. I think the 27 year old wiring is brittle and breaks when the harness it moved around. All I have left to do is to replace fifteen or so splices into the 60 pin PCM connector with new pins. I am waiting on the pins. I tested it and it runs great with the new wiring.

I replaced the ASD output that feeds the injectors, alternator, coil, ASD and O2 sensor. I replaced the sensor ground circuit that feeds the intake air temp sensor, ECT, crank pos, cam pos, VSS, TPS, and MAP sensors. I also replaced all the injector driver wires, the sensor signal wires, and the 5 volt supply wiring to the sensors.

If I get the PCM connector pins and hook them up, and put the harness back in, and the truck still has problems, there will be a lot of cursing in my garage.
Flounder, all I can say is I feel your pain and I'm rootin' for you. Keep us posted.
 
  #13  
Old 07-25-2022 | 09:32 PM
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Well, right at the moment I disconnected the battery to reset everything and I will be reconnecting it tomorrow to see if that doesn't clear some of the codes. Also I think I've got to check the vacuum lines again as well. My wiring harnesses look to be in fairly good shape for their age but if things keep acting funny I'll start replacing them. thanks for the input it does help me out a lot. It is slow work because I have limited time to work on it.
 




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