Contour Enthusiasts Group Archives Forums General Troubleshooting Underhood Wire Harness Recall 95 LX

If I recall correctly, the recall instructions do not say anything about some system failing because of the wiring. I suggest that you ask to see the recall itself and read for yourself what is supposed to be done. Then you will be in a better position to discuss it with them. I think that if the wires are loosing their insulation and you are still within the time and milage constraints, they should replace the looms. They should know this, but since they don't, you may need to do a little more homework.

I think they should replace the looms regardless of whether they are losing their insulation. Because if they aren't now, they will in the future.

As I've mentioned in the past, there are two types of insulation used on "primary wire", PVC and crosslinked polyethylene.

PVC is only rated for temperatures up to 176F. It is easy to see why PVC would not be a good idea for under-hood applications, given this temperature rating.

Crosslinked polyethylene is rated for temperatures up to 257F. This temperature rating is far more suitable for under-hood use.

I went to a u-pull-it yard and pulled a wiring harness off of a '95 Contour with the Zetec. The harness looked to be in good shape, the wiring is not stiff and it is not cracking. I initially thought the harness had been replaced under the recall.

I decided to apply a soldering iron to one of the wires on it. The soldering iron melted right through the insulation, which is characteristic of PVC insulated wire. Had that wiring harness been in use long enough it would have started cracking. I guarantee it.

I applied the same soldering iron to one of the wires on a harness from an '89 Mustang I have laying around. The insulation did not melt (despite holding the soldering iron against the wire for far longer than I left it on the Contour harness), meaning that the Mustang harness is insulated with crosslinked polyethylene. That harness would never start cracking, because the insulation can handle the heat.

Brian

Thanks guys, I really appreciate your help. There were a few more issues I had to take up with the dealer owner (whom I know) and will hopefully be getting a refund on the diagnostic fee. Harrup, I have been to alldata and had a print out of recalls and service bulletins, but I didn't know that by subscribing you could get the info on the wire harness in particular. I will call that 800# you gave me. It is really sad that Ford doesn't pay the mechanics enough to change things but like the guy told me he could change it in five hours if he worked straight through, but he's gotta a take a break, eat lunch, you know how it is. And yes, that is what he told me. Sad, but now I know. Thanks again you guys. I will keep you posted.

By the way, I discovered that the Zetec harness I got from the u-pull-it yard IS cracking...at the coolant temperature sensor connector. Kinda makes sense, doesn't it? That connector probably gets hotter than anything else when the engine is running, so that's where it starts.

Just use a paperclip or a jeweler's screwdriver to push the rubber wire seal away from the connector shell, and look inside.

I'm gonna inspect the one on the '96 sometime soon.

Brian


I had the wire harness recall done on my 95gl 2.5

I had a 112,000 at the time it was done. I had to pay 20% of the costs - Ford Area rep offered this and I accepted (nice gal!)

I was having engine problems and found the fuel injector wiring harness corroded (picture included) went and bought one from Ford for $570.00. I did get a refund on this from Ford. If you want any future reliability from your car, you need to have the wiring harnesses replaced. It will make a world of difference. Ford really made a mistake by using cheap materials in these wiring harnessess.

So is the new harness using different insulation on the wires?

The correct insulation feels somewhat "rubbery"...it's definently noticeably different from what Ford used on the original harnesses.

Brian

Well I did check that out and it "seems" different to me! But them again I am no electrical engineer specializing in insulation composition and the properties thereof!!!! - at least I couldn't find any tags that said made in Japan.

Bob

A soldering iron won't melt the correct insulation. That's the only way I know of to be sure.

Brian