[Shotimes] O/D switch repair update

[Paul L Fisher]

Wow! Good job! I had bought a new harness and after it sat there for a year,
I paid my local mechanic to put it in. He charged me 1 hour labor.


Paul L Fisher

1999 Ford Taurus SHO TR 65K - Kirk'ed 2/29/04.

 - Amsoil Series 2000 0W-30
 - Amsoil TS-124 Oiled Foam air filter

Visit my website: http://www.paul-fisher.com
SHOClub Member: http://www.shoclub.com
Amsoil dealer: http://www.paul-fisher.com/oil


-----Original Message-----
From: shotimes-admin@autox.team.net [mailto:shotimes-admin@autox.team.net]
On Behalf Of Roush, Norman
Sent: Friday, May 14, 2004 12:06 PM
To: shotimes@autox.team.net; Bay SHO
Subject: [Shotimes] O/D switch repair update

Background: My OD light and function became intermittent so I decided to
see if I had the chaffed wire issue.  I removed the console and while
pulling back the stress relief mesh I found that both wires of the OD
harness had broken.  I tried fix it with solder but these are little
20-22 gauge wires and in tight quarters this was impossible.  I
considered butt crimping them together but thought getting a new harness
was a better solution.

Update:  I bought a new O/D switch harness, Ford P/N F5LZ-7E276-AA, for
$27.22.  Using the FAQ at http://tinyurl.com/2ylba and some help from
Kevin Airth I just replaced the entire harness with following these
steps.

1) With key in on position, disconnect negative battery cable
2) Remove the CD storage cover by removing the three Philips head screws
to make removing the shift console much easier
3) Remove the single torx head screw that is located under the rubber
cup holder liner then lift the middle section of console.  Keep track of
the six little metal clips that should stay on the console connecting
pins
4) Disconnect the electrical connection and set console aside
5) Move shifter back in D1 position
6) Remove U clip from shifter. This is found in the cut in the leather
in the front of the shifter. A small flat screwdriver is needed
7) Carefully remove entire O/D switch, not just the O/D button.  Use
needle nose pliers.  A small flat screwdriver may be needed to move the
leather out of the way
8) Remove the shift selector plate by removing three (3) hex head bolts
9) Pull up selector plate and remove light and harness
10) Disconnect O/D harness from connector in console.  Mark the
positions of the two small cable clips and remove both
11) Carefully pull up on shift lever and remove
12) Note orientation of old harness in shift lever
13) Pull out the harness from the shift lever
14) Insert new harness in shift lever.  Use needle nose pliers.  NOTE:
Original harness was kept in place by an extension located on the back
the O/D switch that fit into a notch in the harness.  The new harness
did not have the same notch so it is possible that the new harness could
slip out while installing shift lever.  Be careful.
15) Slowly and carefully re-install shift lever on post taking care not
to kink new harness.
16) Insert U clip.  It may take a little wiggle action to find the
indents cut into the shift post.  Be patient.
17) Connect the harness two pin connector with the mating connector in
console.
18) Slip harness into the two small cable clips
19) Move shift lever back and forth several times to be sure harness
does not catch on exposed bolts or brackets
20) Re-install light and harness in selector plate
21) Make sure selector indicator fork engages pin on selector lever and
re-install selector plate
22) Re-attach console by reconnecting electrical connection, carefully
pressing console in place and screw in torx screw
23) Re-attach CD storage cover
24) Re-attach negative battery cable
25) Test drive and test O/D function

New harness - $27.22
Time invested - 45 minutes
Knowing I can still work on my SHO - Priceless

Norman
95 ATX
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