Have a look at the highmount light, the wires chafe and get grounded, try repairing that short, it may clear up the other issues since the wires go thru the multifunction switch.
Repair the rub spot and buy some conduit to cover it with.
BRAKE LAMP CONCERNS
TECHNICAL SERVICE BULLETIN
Reference Number(s): 05-6-19, Date of Issue: April 4, 2005
Related Ref Number(s): 05-6-19
BRAKE LAMP CONCERNS
Some 2003-2005 Ranger Super Cab vehicles may exhibit brake lamp concerns, fuse 2.13 open on
2003 Rangers, and fuse 2.19 open on 2004-2005 Rangers. This may be caused by a wire chafe at
the rear high mount stop lamp.
Repair the wire harness at the rear high mount stop lamp. Add protective convolute to the wire
harness to prevent reoccurrence. It is not necessary to disassemble the interior to access the
harness. The harness can be accessed by removing the rear high mount stop lamp only. Refer to the
following Service Procedure.
NOTE: THE SHORT WILL OCCUR AT C927 ON 2003 RANGERS AND AT
C904 ON 2004-2005 RANGERS.
Remove the rear high 1. mount stop lamp.
Carefully pull the lamp away from the body, and all of the loose wire harness from inside
the roof panel.
Inspect the wire harness near the connector (Fig. 1 ) to determine if there is a short to the
roof panel inner support.
Fig. 1: Location On Wire Harness Chafing
If no chafing is found, follow the diagnostic procedures found in Section 417-01 of the
Ranger Workshop Manual.
If chafing is found, repair the damage and install a 2" (51 mm) piece of 114-318"
diameter convolute (obtained locally). Push the convolute all the way up the harness
to the connector (Fig. 2 ).
Fig. 2: Convolute Installation
4. Secure the convolute to the harness connector with electrical tape (Fig. 3 ).
BRAKE LAMP CONCERNS -2004 Ford Ranger Page 1 of 2
Fig. 3: Convolute Secured To Harness
Reinstall the rear high 5. mount stop lamp.
For 2004-2005 Rangers, install a new 20 amp fuse into the F2.19 location of the Smart
Junction Box (SJB). For 2003 Rangers, install a new 20 amp fuse into location F2.13 of the
Central Junction Box (CJB).
7. Test the brake lights for proper operation.
Part Number Part Name
Obtained Locally Convolute
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
Basic Part No. Condition Code
BRAKE LAMP CONCERNS -2004 Ford Ranger Page 2 of 2
Sunday, May 17th, 2009 AT 8:46 AM