Just sitting here talking to a co-worker talking about his woes with his FoMoCo product...


1997 7.3 PSD -- literally only a couple of hundred miles out of warranty had a wiring harness burn up, which in turn shorted out a computer. The truck would surge on idle and buck in gear and was taken in for the problem where a tech discovered the aforementioned bad wire(s) and shorted out computer. It's looking like it will cost him close to $1000, as they will not give an inch even though he just eclipsed 100K miles less than one tank of fuel ago.


Anybody here know of any relevant TSB's or recalls concerning something like this?


I would think that this is not supposed to happen...granted the harness was undisturbed and in the factory stock location. I can only speculate that the location was not exactly ideal and that the harness slowly cooked over time until the damage was great enough to cause this problem. Any help and my co-worker would greatly appreciate it.

Since his truck is a 97 he is past his 5 year warranty. If his truck were a few years newer Ford may have given him warranty since he was close to the 100K mark.


I've heard of this hapening before but don't have any advice.

As has been mentioned he was at least 2 years out of warranty. Injector harnesses do burn up on PSDs but it is not common. The computer does not hook to the harness so I doubt it is damaged. The Injector Driver Module may be damaged. It is time for your friend to find a better dealer or get his hands a little dirty. Changing the harness is not all that difficult. It is integral with the valve cover gasket and replacing it is merely replacing the gasket along with demating and mating some electrical connectors. The best place to get gaskets is from an International Dealer. IDMs can be found in wrecking yards or on ebay for about $100. Total cost should be less than $250 plus labor.


A recent thread in the 94-97 forums on www.thedieselstop.com (http://www.thedieselstop.com) talked about harness replacement.

Thanks all,


I was unaware as to if he had some kind of seven year warranty that some manufacturers or after market suppliers offer. The info provided here regarding the valve cover harness and module is consistent with what he has learned at other BB's. I'll pass this on to him. Hopefully it will be helpful as the truck is still in the shop and he is planning on making a surprise visit later today.


On his behalf, thanks again.

The only diesel that has a seven year warranty is the Duramaxes that are covered for the seven year 200K miles on the injectors only. Other than that the big three covers the Duramax, Powerstroke, and Cummins for 5 years and or 100K miles.


Most diesels will be out of warranty after five years due to mileage. I drive over 60K miles a year so if I bought a new truck my warranty would be good for less then a year and a half, which kind of stinks.





Your friend should buy a Haynes repair manual and just get his hands dirty and save a nice stack of $'s.Edited by: dougger222