these are sections from the trans wire harnessgoing toOD solenoid and Neutral safety switch that had shorted my PCM out and caused my agrivating dilema of no dash guages, and alternator shut down. section of degraded conductors was aproximately running 2 feet from the OD and N safety switch connectors to the top of the trans.







this is the OD solenoid connector located at the tail end of the trans just before the U joint.






wire harness before removal







good section of harness from behind the engine







1: 3 wire OD solenoid connector
2: 2 wire Neutral safety switch on top of trans

these were bare copper to connector. I soldered new conductors and used heat shrink to insulate.






existing factory splice of same wires that had malfunction









I used 16/2 extension cord to replace the wire harnes sections. routed cord sections down inside frame.






OD solenoid connected with repaired harness. wrapped with split loom.






orange and black cords on left are new harness sections I soldered in.
yellow split loom is encasing existing trans harness conductors that are still good. (removed the friction tape)
the plug/ sensor you see in the foreground is the trans temp sensor. wire is good there.







splice soldered and heat shrinked...










I would like to thank everyone who contributed to the trouble shooting of my issues. most of us suspected faulty sensors or PCM.

took some hard looking to find the degraded harness.

 

Kev. Wish you had found this before you spent money that you didn't have to spend. But I guess you think the same thing...Hey, at least you got a good hat and koozie out of me...

 

Dave


thank you for all your time and help !

The hat is a new wardrobe accessory every day

 

Good on ya! [8D]

 

Glad you found it. Wiring problems can be a big pain in the rear. Looks like your repair is probably better quality than the original was. How did you make out on your charge air hoses? Did you find any? Kind of an offbeat size compared to the new vehicles now being made.

 

How did you finally come to the conclusion that it was bad wires? PROPS to you Kev for not giving up !! I think I would have a LOOOOONG time ago.

Way to go brotha !!

 

THANK YOU for the compliments guys!!!!

after replacing the PCM and CRANK SENSOR, I rolled the truckgently to the dealer where I have good contacts with a service mgr and the diesel mechanic.

the mechanic dusted off his special chip to read my pcm. it coded FAULTY NEUTRAL SAFETY SWITCH. he crawled below (with truck idling) to look at theNSS connector. touched the wires and it arced which caused the PCM to shut down the truck. figured it was just a small spot. when I got home and tore into it, the factory friction tape fell off to the touch and the wire insulation followed suit.

after some frustrating moments, I was able to find GOOD conductor and cut the bad off. 5 of 10 or so conductors in the harness were fried.


btw...I was ready to let the truck "meet its maker" [sm=badbadbad.gif][sm=violent053.gif] TRUCK [sm=shootshoot.gif]




my next thing is new tires and an alignment.