WARNING: This page is about a different car, the 2000 Ford Windstar and 1999 Ford Windstar. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Following procedure must be used to ensure proper repair is performed on bus wiring. Bus wiring is sensitive to moisture and oxidation and must be properly sealed to ensure proper operation. Regular heat shrink tubing is NOT sufficient, heat shrink tubing containing hot melt wax is required.

When performing a repair on the bus wiring of the module communication network, ensure the wires on the bus are twisted at a rate of 33-40 winds per 3.3 ft. (1 m). The twists should start within approximately 4.9" (124 mm) from any connector. Use only 20 AWG standard wire gauge for repairs.
If performing a splice in the wiring, strip .75" (19.0 mm) of insulation from one wire and 1.50" (38.1 mm) of insulator from the other wire. Perform STEP 1 in illustration. See Fig 1 . Place hot melt wax heat shrink tubing over one wire.
Twist stripped portion of the wires together. Solder connection using resin core RMA solder. DO NOT use acid core solder. Bend wires to allow installation of heat shrink tubing. Perform STEP 2 in illustration. See Fig 1 .
Position heat shrink tubing over splice area. Using heat gun, evenly heat the heat shrink tubing until wax flows from both ends of heat shrink tubing.

Fig 1: Repairing Bus Wiring

Courtesy of FORD MOTOR CO.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Repairing Bus Wiring

Use the Manual With the Right Hardware

When to See a Mechanic

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