Communication Circuit Wiring Repair

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Disconnect the battery ground cable (14301).
Strip the wires.

Fig 2: Stripping Wires
Courtesy of FORD MOTOR CO.

NOTE: Use rosin core mildly activated (RMA) solder, not acid core solder.

Fig 3: Soldering Wires

Courtesy of FORD MOTOR CO.

Solder the wires.
1. Install the heat shrink tube.
2. Twist the wires together.
3. Solder the wires together.

NOTE: Wait for the solder to cool before moving the wires.

Fig 4: Bending Wires Back In A Straight Line

Courtesy of FORD MOTOR CO.

Bend the wires back in a straight line.
Position the (A) heat shrink tube over the (B) wire repair.
- Overlap the heat shrink tube on both wires.
Fig 5: Positioning Heat Shrink Tube Over Wire Repair
Courtesy of FORD MOTOR CO.
Use Heat Gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube.

Fig 6: Heating Repaired Area
Courtesy of FORD MOTOR CO.

NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.

Reconnect the battery ground cable.