Electrical issues...

[Vaughn Golden]

Hello, I've decided it is time to address some issues that I am having with my truck.



I have a 2002 Sport Trac that has the factory Pioneer sound system. The driver door speaker has not been working since I bought the truck in 2012.



Now I am facing a couple of other issues on the same door. The truck will not register that there is a door open when the driver door is opened and just recently the windows in the doors have stopped working completely.



At the time of posting this, I am looking at the wiring with the door panel off to see if I can find any broken or damaged wires. I would like to test if the switch is even getting power but I don't know what wires to test and the Haynes repair manual I have is not doing me justice here.



I suppose that I should also note that the truck has 29100 Km on it (180197 Miles) and all fluids have been changed within the last 8000 Km.



I would also like to ask if there is any maintenance items that I should do at this mileage interval.





Edit:



Well, looks like I've found my issue...

[Broken External Image]:

 

[Mrlunchbox]

Very common unfortunately. Good luck with the repair!

 

[Kyle Hadfield]

Looks like it's been attempted before-the butt connector already there. My suggestion is to add just enough slack (new wire) and solder.



I believe the blue/black is the power window (I had that issue) and the Orange/green is the speaker-I think or the power mirrors (also had that issue) I also had a lt blue/(white?) maybe that was speaker



What I did to get just enough slack but not more bulk than needed was fish new wire from the inside and make the solder in the boot. Then, with some slack as not to pull on the connection, cut my wire to length by the kick panel. Also make sure to leave enough wire to give room to solder. Then to the next. This way any slack/bulk from new wire is inside the kick panel rather than the boot. I'd take that connector off and solder that too. I also had to do this whole process twice-removing everything and opening the boot because I didn't, apparently, check the wires thoroughly enough the 1st time. I suggest looking at each individual wire as far from door connector to inside boot as you can, don't make my mistake to just notice the obvious broken wires.



Not hard to do, just cramped

 

[Vaughn Golden]

Well, I got it all fixed up. The first three wires I repaired were the ones that were obviously broken. I soldered extensions on the wires coming from the truck's harness but later found out that it would be easier to solder onto the wires coming from the door connector.



[Broken External Image]:



I just taped the wires to a screw driver that I had pushed through the rubber and pulled them through.



[Broken External Image]:



I tried soldering the window power wire first but I couldn't hold it in place so I resorted to using some butt connectors that have heat shrink on them. (unfortunately I don't have anymore pictures) Because of the bulk of the butt connectors, I soldered the rest of the wires at the door connector to save space and used the butt connectors in the kick panel. Again, I would have soldered all the wires but I don't have a good way of holding the wires together. So on most of the wires, I soldered the door end to save space in the rubber and crimped the connection in the truck then heated the heat shrink so that everything will stay nice and dry.



Now all my windows work, my driver door speaker works and, the truck now knows when the driver door is open.

Problem solved! :banana:

 

[Kyle Hadfield]

Good job and saved you a couple hundred $



Space is extremely limited, I'm pretty sure I twisted the wire ends together (not to make a pointed end but keep as a straight line, if that makes since). Then put the wire between pinky finger to tug it tight and have the solder in same hand (pointer) to feed and iron in the other hand. I could of used a pair of needle nose to hold wires steady and feed at the same time. It surely wasn't fun BUT it was satisfying!