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Old 04-03-2013, 02:48 PM   #1
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Question Corroded wires next to battery.

Anyone else had this problem?

My wife's 2005 Wrangler SE, 2.4L has been diagnosed with a corroded engine wiring harness and told that it might not be worth fixing! She takes care of the car, I do the major maintenance items but find it incredible that an 8 year old vehicle could have this happen.

We're hoping the shop can repair the few actually failed wires but that seems to only be a short-term fix.

Other than my first question, does anyone have experience replacing any of the engine wiring harnesses? How hard are the harnesses to get? And how bad of job would this be to do myself? (I have rebuilt transmissions, turbos, etc, etc.)

Any recommendations for where to get a replacement harness?

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Old 04-03-2013, 03:45 PM   #2
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check eBay Amazon 4wd.com and your local parts stores. ive replaced whole harnesses before and if you take your time and Mark everything its pretty simple and easy going. I couldn't believe that something that young would have so much corrosion that it wasn't fixable. not when ive got a 75 dj5 with the original wiring still running. I'd start trying to find why it is doing this ASAP so you dont go fixing it just to have to do the work again.

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Old 04-03-2013, 05:33 PM   #3
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Great, that's what I'm hoping in terms of replacement - take my time, label everything (I might even photograph / videotape the removal process) and hope there aren't too many inaccessible spots. We're told it's the computer harness and the PCM might be damaged too!

They also said it might have been the previous battery that leaked so much, and that the battery is supposed to be cleaned when it's inspected and it looks like that was never done. He said batteries leak whenever they are being charged, a small amount. Bad design on Chrysler's part.

So at least we now know to keep a close eye on that area and make sure it's clean at all times.
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Old 04-03-2013, 07:29 PM   #4
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Quote:
Originally Posted by Grusvag View Post
Great, that's what I'm hoping in terms of replacement - take my time, label everything (I might even photograph / videotape the removal process) and hope there aren't too many inaccessible spots. We're told it's the computer harness and the PCM might be damaged too!

They also said it might have been the previous battery that leaked so much, and that the battery is supposed to be cleaned when it's inspected and it looks like that was never done. He said batteries leak whenever they are being charged, a small amount. Bad design on Chrysler's part.

So at least we now know to keep a close eye on that area and make sure it's clean at all times.
If that is a bad design on Chrysler's part, they share it with about a bazillion other manufacturers. I don't know of any cars in recent memory that come from the factory with a "sealed" AGM style non spillable battery.

I know batteries are a very touchy subject when it comes to favorites and my only advice to anyone with a vehicle they care about is to dump the lead acid engine and harness destroyers and get a "sealed" non spillable AGM style battery regardless of brand.

If you noticed me putting sealed in quotes, do some research on AGM. While promoted as non spillable they are not air tight which doesn't matter as the acid will not leak out.
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Old 08-08-2015, 12:06 AM   #5
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Hey Grusvag, I came across your thread about the corroded wiring harness on your wife's '05 Wrangler. I've had a similar issue with mine. I seem to have caught it early enough that they're not corroded through, but they sure didn't look good. Just wondering if you have any pics you can share & what the outcome is/was.

My 2003 was throwing some codes (O2 Sensor and Coolant Temp Sensor). After replacing those they kept coming back. So, I took it back to the original tech, who checked them again. He said that even when disconnected, their scanner was still getting a reading from those sensors. He assumed it's a bad PCM. A few days later I discovered corrosion on the wiring harness - right next to the battery. The harness looked a little wet & sure enough, the cloth tape just disintegrated in my hands, even as a white, chalky powder seemed to coat most of the wires in that section. I shot some still and video to show my mechanic.

So, the owner and main tech took a look and cleaned up the wires. I watched him do it. Since none were corroded through, he wasn't convinced that was the issue. For better or for worse, the Jeep seems to be idling fine now and no codes - so far. I even watched the O2 sensors on a borrowed scanner. The readings seemed normal (constant fluctuating between roughly .2 and .8 volts). Still, it seems REALLY odd that just cleaning them off would solve the issue.

Now, I'm waiting for the other shoe to drop and the codes to come back. Just hoping my Jeep doesn't catch fire in the process. I can't imagine how cleaning the outside of the wires (none were corroded through, but are clearly grey & puffy) could possibly fix this, other than somehow "jiggling" a good connection out of a bad connection. If that's the case I imagine it'll jiggle itself bad before long. I'm taking it to a dealership on Tuesday just to be safe.

So, again, would love to see pics if you have any. If anyone else has any thoughts on how/why a scanner would give a false reading of an O2 or coolant temp sensor, I'd love to hear it. Is it possible those corroded wires & NOT the PCM were causing the issue? What about heat or chemical reaction generating a current/ signal back to the PCM, such that it was giving a false reading?

I'll post pics of mine (if I can figure out how). Apparently I need to host them on another URL?? Odd.
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Old 09-19-2015, 01:48 PM   #6
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Well, a month later & no more codes. Weirdest thing in the world. Jeep runs great. Took a road trip at the end of August, no issues & even got great gas mileage. (I cleaned the Raid Air filter before I left but imagine the new 02 sensor may have helped some too).

Still a mystery to me. A friend suggested the wires may have been "bleeding" current. Don't know about that, but if anyone has any insight, would love to hear it.
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Old 09-19-2015, 02:06 PM   #7
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The bus connections run a twisted pair and is pretty sensitive to stray signals

When jeep did a TSB to replace the instrument cluster connectors they just cut and spliced all the wires including the two bus connector wires and some guys claimed they got no bus errors until they cut one and re twisted that distal portion of that spliced connector short harness for the twisted pair, never seen it myself but a nice grounded shield would have made the twisted pair bus signal more robust so I think your explanation is plausible as we are not just talking straight DC 5 and or 12 volt current

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