Repairing Bus Wiring

WARNING: This page is about a different car, the 2002 Lincoln Navigator, 2002 Ford Expedition, 2001 Lincoln Navigator, and 2001 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The following procedure must be used to ensure proper repair is performed on network communications wiring. Network communications wiring is sensitive to moisture and oxidation. Network communications wiring must be properly sealed, to ensure proper operation of module communications network. Regular heat shrink tubing is not sufficient. Heat shrink tubing containing hot melt wax is required.

NOTE: When performing a repair on Standard Corporate Protocol (SCP) network, ensure bus wires are twisted at a rate of 33-40 winds per 3.3 ft. (1 m). The twists should start within approximately 4.9" (124 mm) from any harness connector. Use only 20-gauge standard wire for repairs.

Disconnect negative battery cable. Strip .75" (19.0 mm) of insulation from one wire and 1.50" (38.1 mm) of insulation from other wire. Perform STEP 1 in illustration. See Fig 1. Place hot melt wax type heat shrink tubing over one wire.
Twist stripped portion of wires together. Solder connection using a rosin core mildly activated solder. DO NOT use acid core solder. Bend wires to allow installation of heat shrink tubing. See Fig 1.
Position heat shrink tubing over splice area. Using heat gun, evenly heat up shrink tubing until wax flows from both ends of heat shrink tubing.

Fig 1: Repairing Bus Wiring

Courtesy of FORD MOTOR CO.