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Old 11-08-2015, 11:29 AM   #1
JWA
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Potential Wire Chaffing

Found this while digging into my wiring bundles in advance of adding a factory tach cluster:



This occurred because this wire bundle has been rubbing against the back side of the degas bottle for who knows how long. Its such a tight fit anyway, the bundle having to be pushed backwards when the bottle is fastened to the fender and cowl.

My solution is completely non-elegant but should eliminate further rubbing:



Next time you're poking around under the hood and have a few moments along with an 8mm socket take a quick look---that bundle goes into the PCM.
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Old 11-08-2015, 01:04 PM   #2
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Re: Potential Wire Chaffing

Noted and will be addressed for sure...thanks.
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Old 11-08-2015, 01:07 PM   #3
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Re: Potential Wire Chaffing

Glad this might help someone. I'd hate to think this become more of an issue out on the road or like some of y'all deep in the woods etc.
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Old 11-08-2015, 09:33 PM   #4
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Re: Potential Wire Chaffing

Thanks for the heads-up!

I found this chaffing problem while swapping out my radiator this weekend. It's not as scary as rubbing threw wires but something 6.0 PSD owners should look out for. This is the intercooler hose on the passenger side.



It has been rubbing on the AC line. You can see the metal has wore through but not leaking.



But they were not touching when the engine is not running or even if it was running while in park. So they were just close enough to contact when driving.

I bent the AC line mounting backed in order to move the AC line away from the intercooler hose. Then just in case, wrapped the AC line with a bit of rubber hose. Now there is 5/8" to 3/4' between them, that should be enough.



Just one more thing to look out for before it becomes a real problem. This hose is not cheap!

Cheers,
John
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Old 11-08-2015, 11:32 PM   #5
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Re: Potential Wire Chaffing

While we are on the subject of chaffing, here is another problem I recently had. There is this coolant line that goes over the top of the engine from drivers side to passenger side into the hearer core. The metal part of this coolant line was rubbing on the aluminum insulation just above the engine. It wore threw and started leaking coolant.



This was a $190 coolant line.
We all know these engine compartments are tight but things like this shouldn't be happening.
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Old 11-09-2015, 04:44 AM   #6
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Re: Potential Wire Chaffing

John both instances show us despite making a good quality van some manufacturers overlook or are never made aware such things are either built in or can develop over time. Even though I've had my degas bottle out before doing something or adding wiring behind it until this weekend I never noticed my situation.

Maybe the take away here is as owners we have to look at nearly everything at least occasionally, hopefully to catch things like this before they knock us out of service unexpectedly.
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