WARNING: This page is about a different car, the 2002 Mercury Grand Marquis and 2002 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The 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 of module communications network. Regular heat shrink tubing is NOT sufficient, heat shrink tubing containing hot melt wax is required.

When performing repairs on bus wiring, ensure wires on bus are twisted at a rate of 33-40 winds per 3.3 ft. (1 m). The twists should start approximately 4.9" (124 mm) from any connector. Use only 20 AWG standard wire gauge for repairs. Go to next step.
If performing a splice, strip 0.75" (19.0 mm) from one wire and 1.50" (38.1 mm) from the other wire. See STEP 1 in Fig 1. Place hot melt wax type heat shrink tubing over one wire and go to next step.
Twist stripped portion of wires together. Solder connection using resin core RMA solder. DO NOT use acid core solder. Bend wires to allow installation of heat shrink tubing. See STEP 2 in Fig 1. Go to next step.
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. See STEP 3 in Fig 1.

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