No Start, Starter Inoperative, ABS Lamp On, Exhaust Brake Lamp On, Various Electrical Conditions (Repair Chassis Harness)

Some customers or dealers may comment on various electrical conditions with the vehicle. Some of these electrical conditions may include, but is not limited to, vehicle no-start, starter inoperative, ABS Lamp on or Exhaust Brake lamp on.

The cause of this condition may be from water and dirt intrusion into the chassis wiring harness, causing corrosion of wiring splices or the wires themselves. Water and dirt may intrude into this area due to water not draining from the harness (see illustration above) or a modified or damaged mudflap coming into contact with the wire harness conduit, chaffing or damaging the conduit. The location is in the chassis harness (1), approximately 203 mm (8 in) from the relay box mounted behind the left front wheel where the harness dips below the frame. See the above illustration. The conduit is sealed by electrical tape, not allowing water to drain from the harness. The exposed location of this harness may make it more susceptible to the elements.

Notice: If the mudflap is modified or becomes damaged making contact with the harness, repair the mudflap to insure it does not interfere or come in contact with the wire harness conduit.

Repair the chassis harness at the above location using the following steps:

1. Remove the electrical tape wrapped around the conduit.
2. Remove the harness and inspect for any water or dirt intrusion. Also inspect and repair any affected wires that may be corroded or chafed. Refer to the applicable Service Information for wiring repairs.
3. Install the harness back into the conduit and retape, leaving approximately 50 mm (2 in) of the split exposed at the lowest portion of the conduit in order to allow drainage. Ensure that the split of the conduit is facing downward, allowing any further water intrusion to drain.

For vehicles repaired under warranty, use: