HELP! 06 F250 6.0 Chafed harness - Ford Powerstroke Diesel Forum
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post #1 of 3 Old 12-11-2010, 07:14 AM Thread Starter
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HELP! 06 F250 6.0 Chafed harness

Hello All!

My truck has been throwing codes on and off for the past couple months. I was told that since they come and go that they are "soft" codes not to worry.
Flash ahead to now and my truck is dead in my driveway.

After some snooping around I noticed that the GPCM wire harness to the PCM plug closet to the front is majorly chafed! I have a neighbor who is an electrical engineer who is willing to help with the repairs but the weather in the chicago area has been BRUTAL lately! I forgot to add while I was snooping around I managed to break off a plastic retainer on the actual connector to the pcm and the 4 black retaining clips on the retainer/protective cap were smashed already.

I went to my local ford dealer and of course they said there is not a repair kit for that area of the harness. Is this true? I had the schematic from the Ford Bible and was pointing to exactly what I need. If there isn't a repair kit out there what is the best way to repair or correct the bad wires?

I had the typical FICM, GPCM codes and a fault circuit on injector #5. I put some seafoam in my fuel and it cleared up #5. I have heard that the wiring harness is and isn't under warranty. I have a stage 2 afe intake and that is the only reason I haven't had it yanked to the dealer.

Any suggestions and/or help would be greatly appreciated.
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post #2 of 3 Old 12-11-2010, 07:47 AM
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What I would do is, find a "U-pick-it" type of junkyard near you and get one of those wiring harnesses myself or give a junkyard a call and ask for the specific harness.
Try: to find one


First I would be addressing the spot where it chafed. Find out why and remedy that, then repair the wires that were affected. Then go to the "U-Pick_it" and just hack out the plug that you need. You will have to get the right tool to release the individual terminals within the plug. Take your time and do 1 terminal at a time and be 100% sure you have the right terminal in the right spot.
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post #3 of 3 Old 12-12-2010, 03:45 PM Thread Starter
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Thanks! I'm going to check that out asap. I'm lucky enough to have a back up but it's a 98 k2500HD Cheyenne with a bench seat that is past worn out!
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chafing , engine wiring harness , ficm , gpcm

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