Quote:
Originally Posted by Shusterm
Friends,
I just bought a 2019 5.0 and while driving it home, my truck showed no brakes connected. I began trouble shooting by looking at my truck first and all checked out. Then I pulled the cover off of the terminal box on the hitch. (See picture). I found the blue wire had pulled out of its terminal. I re-crimped the terminal to the wire reinstalled and everything worked. It is worth a look.
Mike
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Uh, someone used the wrong crimper on those lugs! Insulated lugs use a different crimp than uninsulated ones.
From the internet: "Crimpers for insulated terminals have rounded jaws designed to avoid damaging the terminal insulation. Using an uninsulated crimper on an insulated terminal could damage the insulation sleeve or lead to an under crimp or an over crimp."
That big dent in the lug shows that the tech used the uninsulated crimper jaws to do the crimp - and that is why those crimp connections may fail over time.
Also, take a look at the main 12v red wire - they cut off strands from the wire to get it to fit the undersized crimp lug. Several of the yellow lugs are crimped to smaller wires than the lug is rated for - again, bad practice.
You will need to redo all those crimps to make them reliable using the correct sized crimp lugs. My suggestion is to use uninsulated crimp lugs (or pull off the insulation sleeve) crimped, then soldered, then heat shrinked. Below is a pic of what I'm suggesting.