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Old 11-01-2012, 02:37 AM
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skyskijason skyskijason is offline
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Default Fix the OD switch wire short - BEFORE it fails!!!!

This applies to all '99 - '03 7.3's:

Finally made time to fix this pesky little problem. I will echo the scores of X and Super Duty owners who have said repeatedly over the years to FIX this BEFORE the wires get chaffed enough to short... I didn't listen even though I knew about this when I bought the X and waited for it to fail.

The problem:

The wires for OD switch travel thru the shift lever and after exiting they cross over the top of the column and plug into the wiring harness. Since these wires need to allow the shifter to move as well as the steering wheel to tilt - the wires also move when these things are moved. As the wires move back and forth this 1/4", they eventually wear thru the insulation and expose the wires. Initially, my OD lite would come on for no reason and eventually I was blowing fuses when shifting or using OD switch. As far as I can tell, THIS WILL HAPPEN TO EVERY ONE OF THESE TRUCKS - eventually. Seriously, its an EASY fix if ya do it NOW - it takes 20min, a phillips screwdriver and some tape!

First, remove the (3) screws that hold the plastic trim around shifter. Unscrew the tilt steering lever and remove lower plastic piece. With ignition in 'on' position, press the little shiny ball on the bottom of key cylinder and remove the cylinder.


Now you can slip the upper plastic over the shift lever and get it out of the way.


Since I'm a dum redneck and waited until I had a problem, mine was worn completely thru one of the wires. I was trying to strip it back and repair it in place and pulled the other 2 wires apart where they were crimped at the hold-down thingy attached to this black trim piece.


If I was smarter, I would have just unplugged the wire from harness and removed the pin in my hand and slipped the shifter lever, wire and black thing off so I could take the whole thing out where I could get to it... Don't try to slide that black piece off the shifter, its too big and will tear.
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RIP X & Toyhauler - you served us well.
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Old 11-01-2012, 02:38 AM
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With parts in hand, I sat down at the workbench and soldered the wires back together and covered them in shrink tubing.


This is a 2nd small chaffed area, I put enough shrink tubing over all the wires to cover this area as well.


To finish the repair, I put shrink tubing over the the whole thing and put it back in the truck!!
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2001 F350 XLT 4x4, dually flatbed. 6637 air filter, single-shot injectors, straight-piped, BTS tunes, 200 gal main VO tank - 180k greasy miles
2000 Excursion Limited 4x4. V3, AIS intake, BTS trans & tunes - 120k VO miles
veggiegarage.com authorized installer

RIP X & Toyhauler - you served us well.
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Old 11-01-2012, 02:43 AM
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Here's a link to the rubber boot thingy - dunno which one it is though...
http://www.tousleyfordparts.com/part...component=Seal


Also, the symptoms can be all sorts of things from blowing PCM fuse to wacky dash and loss of throttle position sensor. I had a flakey OD lite for awhile before mine went tits up. If you too procrastinate and wait until this is a PROBLEM - you can just unplug the switch harness and replace the fuse (if needed) and drive on home.
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2001 F350 XLT 4x4, dually flatbed. 6637 air filter, single-shot injectors, straight-piped, BTS tunes, 200 gal main VO tank - 180k greasy miles
2000 Excursion Limited 4x4. V3, AIS intake, BTS trans & tunes - 120k VO miles
veggiegarage.com authorized installer

RIP X & Toyhauler - you served us well.

Last edited by skyskijason; 11-01-2012 at 02:52 AM.
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Old 11-01-2012, 03:30 AM
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Is this Just on automatic transmissions?
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Old 11-01-2012, 04:13 AM
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Quote:
Originally Posted by Elvia View Post
Is this Just on automatic transmissions?
Yep.
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Old 11-01-2012, 02:19 PM
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Did mine yesterday out of necessity. Thought I had a major problem as I lost gauge cluster and throttle. After talking things through with Jason, I used about .10 of elect. tape and a fuse. Funny thing is when I called dealership to ask if they knew about the problem they claimed ignorance and told me to tow it in....... That would have cost me time and lots of $.

It literally takes 20 min to beef up that wiring with a little elect. tape

Moderators please sticky this thread
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Old 11-01-2012, 02:30 PM
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Lucky Me...
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Old 11-02-2012, 11:13 AM
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Jason - Really appreciate this post. It's always good to get something fixed before it actually breaks and causes you problems. Thanks. - Patrick
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Old 11-03-2012, 08:07 PM
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Jason helped me fix mine, too. Mine happened to short out when I was camping with him this summer - can't believe how fortunate I was that it happened on that particular weekend.
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Old 10-24-2013, 10:13 PM
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I pulled mine apart the other day and there wasn't any wear on the wire. I put some wire loom around it and buttoned it up. Thanks!
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