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Wire at harness getting hot. |
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Anderslober 
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Joined: 30-July-2019 Location: Denmark Status: Offline Points: 766 |
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 Topic: Wire at harness getting hot.Posted: 01-August-2025 at 9:42PM |
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Hello forum. I chased down a fault with low beam lights not coming on or very dim. I tested everything inside the car, fuse, fuse box, light switch, dimmer switch…..all was good. Still dim/non low beams.
By chance, I wiggled the red wire on the harness connector (engine bay)….and lights came on fine. I did notice the red wire was very hot…..2 inches down the wire was normal temp. I have a feeling the wire may be damaged inside the harness connector….how do I get the wire out of the connector? Thanks.  Edited by Anderslober - 01-August-2025 at 9:59PM |
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peter.jenerette
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Joined: 08-February-2023 Location: Nevada, TX Status: Offline Points: 1054 |
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Posted: 02-August-2025 at 1:27AM |
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IIRC On the wide side by each connector, you can push a jewelers screwdriver or pin in there to depress the locking tab for each connector. It may take some in out wiggling to pull out on the wire side.
I would try cleaning as best I could with it in place on both sides, maybe even try bending the pinch side to tighten them up fore trying to extract the connector, its 50 years old and easier to damage. Good luck!
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Pete Jenerette
1972 Gran Torino (H-Code - 4R70W) 2022 F250 XLT 7.3 2003 Thunderbird |
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72 RS 351
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Joined: 04-September-2014 Location: Knoxville TN Status: Offline Points: 3445 |
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Posted: 02-August-2025 at 1:51PM |
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The terminals will come out of the connectors. It sounds like there is some wiring damage, really brittle or cooked at some points. I don't know how the old OEM connectors come apart, I'm very used to the late 90's Ford wiring. The newer connectors all have a plastic lock piece which is a contrasting color to the connector itself, so it stand out clearly. The older type may not have those locking pieces The terminals are all held in by a tiny plastic tang that you can see looking into the ends as pictured above. A tiny screwdriver or awl can be used to gently move the tip of each tang aside which then allows the terminal to pull out of the backside. The pictured connector doesn't have the locking piece I mentioned, the tangs seen in there should easily be moved and allow the removal of the terminal.
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Don
73 Ranchero "Sport 72 front end", floor shift/console, planning EFI 7000 rpm 351 stroker 73 Ranchero GT 351C-4V &4R70W for sale later. 92 Lincoln Mark VII SE GTC, OBDII 347/4R70W |
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Rockatansky
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Joined: 30-July-2010 Location: On The Road Status: Offline Points: 6398 |
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Posted: 03-August-2025 at 9:28AM |
1st thing i noticed looking at the pic of the connector is some of your terminals are wide open, is the wire you found to be hot one of the open terminals? FYI be careful tightening the 5/16" screw that holds the connector into the back of the fuse block, it's threading into plastic!
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72 GT Ute
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peter.jenerette wrote: