Potential wire chafe area on later model e-series

Matt Saunoras · July 25, 2013

I was warned about this one by another tech who works on mostly 6.0 econolines. He said keep an eye out on the 09-10s

You can see where the harness has pushed down all the way over the intake manifold bolt head. This is directly under the intake tube which is obviously responsible for compressing the harness.

Actually no damage was done yet to this 50k mile vehicle so some extra electrical tape "padding" will hopefully do the trick. One time previously I ran into one that had an incorrectly installed stud in that location that poked up into the harness and shorted out one of the #4 injector circuits.

Aaron · July 25, 2013

I saw one like that awhile back, on an older E-series 6.0

I think I put a piece of sliced open heater hose around the harness.

Keith Browning · July 25, 2013

A couple of weeks ago I had a F-Series where some knucklehead misplaced a stud in that same position. Is it that hard to remember where the studs go? Marking the positions with a paint pen or even a Sharpie will fix that! Also, I have worked on a couple 2009/2010 ambulances where the harness looks like engineering made some changes... there are some new connectors that add locks to the hardshell making them that much more difficult to disconnect. I suppose this re-route over the bolt is an improvement? :thumbup:

Matt Saunoras · July 25, 2013

I have a cheat sheet where I've drawn out the locations of intake studs/bolts on different model years. Not necessary but there's definitely some minor differences year to year.

mchan68 · July 25, 2013

A couple of weeks ago I had a F-Series where some knucklehead misplaced a stud in that same position. Is it that hard to remember where the studs go? Marking the positions with a paint pen or even a Sharpie will fix that! Also, I have worked on a couple 2009/2010 ambulances where the harness looks like engineering made some changes... there are some new connectors that add locks to the hardshell making them that much more difficult to disconnect. I suppose this re-route over the bolt is an improvement?

.... and those would be the connectors for the ECT, EOT and IAT #2 that I have yet to find a part number for a pigtail for. The sensors themselves have not changed.

I have a cheat sheet where I've drawn out the locations of intake studs/bolts on different model years. Not necessary but there's definitely some minor differences year to year.

After having wrenched on so many them, I either leave them in the intake with the intake gaskets secured to them during removal, or I'll remove them outright and throw them in a pile. I pretty much have all stud/bolt locations on these memorized. Ditto for passenger side and driver side valve covers on both E and F Series applications or all years except for the driver's valve cover on a 2003 engine.

Matt Saunoras · July 26, 2013

when an e-series engine is out I will mark the valve cover stud locations. My memory isn't that good yet on these things. I did finally figure out the trick for getting the turbo in and out though.

Brad Clayton · July 26, 2013

^{Shrink ray gun?}

Matt Saunoras · July 26, 2013

I actually boomeranged a turbo drain tube right into our other techs gut the one day. Ran around the front of the engine, snatched it out and whipped it right as he happened to be strolling by. He was largely unaffected by the whole thing, He did let out a comical ooooffff when it hit him though. I proceeded to laugh uncontrollably as I burst into full sprint going the other direction.