Loss of lock and window functions is due to wire bending fatigue at the front dor jambs, usually the drivers side earlier. Attempts to repair some of the wires is only buying limited time extension. There are a few good u-tube videos online. The repair is to address all the wires, relocate the plug connector into the door to relieve the tight bend space. Here are the tips I can offer. Disconnect the ground cable. The connector can be accessed by pinching the ears on the door boot and pulling the connector into the jamb. Make a chart of the wire colors and their corresponding numbered location on the plug, look close, they are there. To disconnect the connector slide the red lock open and depress the connector latch just above it toward the wires. Trace the harness into the cab, below the fuse panel, above the kick panel. What I did was create the chart, cut all the wires leaving at least 2-3 inches to crimp on new. Pull the harness into the cab remove enough to include the break areas. Obtain the correct wire and connectors. I marked corresponding marker lines on the new wires, ie 5 lnes for the number 5 (mine orange /red) to reconnect up inside the cab. I made my new harness about 16 inches long. Wrapped the new harness in a 5/8 wire loom, wrapped wire loom wrap over that. Pop off the door panel after removing the three hard fasteners. Again, check Utube for procedure. Feed the new harness into the cab, through the white boot boor connector, so the boot can be connected. Peel back the corner of the door liner. Push the connector through the door opening. The connector will reside inside the door ahead of the window track. Later make sure it doe not interfere with window operation. Inside the cab cut out no more wire than necessary to rmove the areas of breaks. Make connections, this is why the asbuilt chart and clear marking is important. Use what wire space management desired, plenty of places to tie wrap a new taped bundle out of the way. Remember when checking functions, doors will not lock with the key in and door open. It is not always possible to identify breaks without a meter and some aggressive testing. "Donor" junkyard harnesses are no better than yours. When closing up, shape the wire bundle to allow movement into and out of the door when operating the door. Same inside the cab, reduce the potential to bend. Not all that difficult, buy a few good wire tools, thest the mechanical integrity of connections. Tape or heat shrink as desired.
Wednesday, November 9th, 2016 AT 4:41 PM