Overhead console keeps blowing fuse E (#5)

[ohmsm39]

So after a third attempt at trying to get this overhead console installed (and numerous blown 15 amp fuses) I am looking for additional help. Here's the sitch:

95 Bronco Sport - prewired for overhead console (console unit was not originally installed)

• 99 ford Explored overhead console added (swapped the board into a 02-04 F-150 housing)
• Added the '99 explorer wiring harness from the roof down to the kick panel
• Removed the factory 95 female connector and spliced in the '99 explorer connector
• Added '99 temp sensor onto existing factory original connector (front bumper area)
• Checked wires to firewall - all good
• Wiring:

• Explorer Wires	Bronco wires
  Dark Blue/White: Temp sensor -	BLK/PNK: temp sensor -
  Dark Blue/Yellow: Temp sensor +	BLU/YLW: Temp sensor +
  Grey/Yellow: Hot in run	WHT/PNK: Hot in run
  Red/Black: Dimmer	LT BLU/RED: Dimmer
  Green/Orange: Battery Saver/Maps	GRN/ORG: Battery Saver/Maps
  Black/Blue: Dome	BLK/LT BLU: Dome
  Grey/Black: VSS	GRY/BLK: VSS
  Black: Ground	BLK: Ground

As soon as I plug it in and turn on the car - temperature reads (shows 119˚ incorrectly - location displays correctly)
Fuse E (#5) under hood blows:

E (#5)

Backup Lamps, Daytime Running Light, Trailer Battery Charge Relay, Heater Exhaust Gas Oxygen (HEGO) Sensor, Speed Control [Gasoline]

ABS light fires up constant
If I drive it, I get the hard shifting out of 1st gear (due to the blown E (#5) fuse)

Any thoughts? I've checked and cleaned wires from bumper sensor to main wiring harness - all good

 

[Tiha]

I would probably unplug the VSS wire, clip it. See if the fuse still blows. Be my first guess anyway.

 

[L\Bronco]

So after a third attempt at trying to get this overhead console installed (and numerous blown 15 amp fuses) I am looking for additional help. Here's the sitch:

95 Bronco Sport - prewired for overhead console (console unit was not originally installed)

• 99 ford Explored overhead console added (swapped the board into a 02-04 F-150 housing)
• Added the '99 explorer wiring harness from the roof down to the kick panel
• Removed the factory 95 female connector and spliced in the '99 explorer connector
• Added '99 temp sensor onto existing factory original connector (front bumper area)
• Checked wires to firewall - all good
• Wiring:

• Explorer Wires	Bronco wires
  Dark Blue/White: Temp sensor -	BLK/PNK: temp sensor -
  Dark Blue/Yellow: Temp sensor +	BLU/YLW: Temp sensor +
  Grey/Yellow: Hot in run	WHT/PNK: Hot in run
  Red/Black: Dimmer	LT BLU/RED: Dimmer
  Green/Orange: Battery Saver/Maps	GRN/ORG: Battery Saver/Maps
  Black/Blue: Dome	BLK/LT BLU: Dome
  Grey/Black: VSS	GRY/BLK: VSS
  Black: Ground	BLK: Ground

As soon as I plug it in and turn on the car - temperature reads (shows 119˚ incorrectly - location displays correctly)
Fuse E (#5) under hood blows:

E (#5)

Backup Lamps, Daytime Running Light, Trailer Battery Charge Relay, Heater Exhaust Gas Oxygen (HEGO) Sensor, Speed Control [Gasoline]

ABS light fires up constant
If I drive it, I get the hard shifting out of 1st gear (due to the blown E (#5) fuse)

Any thoughts? I've checked and cleaned wires from bumper sensor to main wiring harness - all good

Heres what I found



Looks like Blk\Pnk you used for temp sensor doesn't belong. When I did my 79 restomod, Blk and Pk was hot in run.
The temp sense neg on the 95 is Lb\O and is grounded under the hood. You will need to run the Lb\O from the ambient sensor to the Db\W on your 99 console harness. (Cut off the ground first. S103 is in the engine control harness near the tapeout to the left front park\turn lamp.)
Hope that helps
Cheers

 

[ohmsm39]

Heres what I found
View attachment 31265View attachment 31266


Looks like Blk\Pnk you used for temp sensor doesn't belong. When I did my 79 restomod, Blk and Pk was hot in run.
The temp sense neg on the 95 is Lb\O and is grounded under the hood. You will need to run the Lb\O from the ambient sensor to the Db\W on your 99 console harness. (Cut off the ground first. S103 is in the engine control harness near the tapeout to the left front park\turn lamp.)
Hope that helps
Cheers

@L\Bronco - What ground am I cutting off? The S103 grounds near the left front parking/turn lamps?

 

[L\Bronco]

Being a 95, it doesn't go back to the console like a 96 does. Your Lb\Or wire changes to black a splice s103 and grounds at G 100. You need to run the Lb\Or wire inside and connect it to Dark blue\White on the 99 harness.
Hope that helps
Cheers

 

[miesk5]

Yo ohms,
Sooooo, we meet again! (Insert grin here)
TSB 95-5-21 Fuse "E" Inoperative - ABS Light On - Back-Up Lamps Inoperative - Daytime running lamps Inoperative (in Canadian Broncos) - MIL (CEL) On - Speedometer Inoperative
LIGHT TRUCK: 1992-1995 BRONCO, F-150-350 SERIES
ISSUE: On some vehicles the HO2S (miesk5 note, this the oxygen sensor) wires in the 12A690 (subassembly of the 14B060 battery cable) harness may become chafed and the vehicle could exhibit any one of the following conditions:
ABS light on
Speedometer inoperative
Back-up lamps inoperative
Daytime running lamps inoperative
Trailer battery charge relay inoperative
MIL on, displaying Codes: 172, 173 or 41 for HO2S failure
Inadvertent PCM Self-Test

ACTION: Replace the damaged wire harness and HO2S sensor. Refer to the following procedure for service details.
SERVICE PROCEDURE:
1. Disconnect negative battery cable.
2. Disconnect the solenoid terminal and positive battery cable from the starter.
3. Pull the cable downward to inspect the 12A690 harness for chafing, pinholes, etc. If necessary, remove the convolute and tape from the 12A690 harness located next to the lower RH side engine mount.
4. If the 12A690 harness is damaged, replace the 14B060 assembly (F5TZ-14300-EA) and the HO2S sensor (F4UZ-9F472-A).
5. Inspect Fuse "E" and replace if necessary (D9ZZ-14526-D).
6. Clear all codes stored in memory.
7. Retest and verify the concern has been resolved.

PART NUMBER - PART NAME
D9ZZ-14526-D Fuse - 15 Amp
F5TZ-14300-EA Harness Assembly

F4UZ-9F472-A HO2S Sensor
In attached diagram;View attachment 212176

Item Part Number Description
1 11450 Starter Motor Relay Assembly
2 N803991-S36 *****
3 14A396 Cap
4 381561-S36 Nut and Washer Assembly
5 14B060 Cable Assembly
6 Starter Solenoid Heat Shield 5.0L/5.8L Only (Part of 11002)
7 382747-S36 ***** and Washer Assembly
8 N805403-S100 Nut and Washer Assembly
9 11N087 Cover — Starter Solenoid (Red)
10 56558-S Bolt
11 34943-S36 Star Washer
12 14301 To Engine Ground
13 12A690 Wire Assembly
14 11002 Starter Motor
15 To Heated Oxygen Sensor for 5.0L/5.8L Under 8500, 5.8L over 8500 and 7.5L F-450
16 N621906-S36 Nut
17 N806925-S36MG Stud
18 12A581 Body Grounds
19 14301 Chassis Ground
20 — For Continuation Refer to Fender Apron, Right, Gasoline Engines Illustration Shown Previously in this Section
21 To Heated Oxygen Sensor for 5.0L/5.8L Under 8500, 7.5L F-450
22 12A690 Wiring Assembly For 5.8L Bronco
23 N802777-S36 Bolt for 14301 Frame Ground
24 9S286 Existing Gas Vapor Tube
25 10655 Battery
26 33799-S2 Nut (Auto Transmission)
27 5A212 Exhaust Pipe
A — Tighten to 7-9 Nm (62-80 Lb-In)
B — Tighten to 21-29 Nm (15-21 Lb-Ft)
C — Tighten to 10-14 Nm (7-10 Lb-Ft)
D — Tighten to 25.5-34.5 Nm (19-25 Lb-Ft)
E — Tighten to 9-12 Nm (80-106 Lb-In)
F — Tighten to 11-16 Nm (8-12 Lb-Ft)

 

[ohmsm39]

Yo ohms,
Sooooo, we meet again! (Insert grin here)
TSB 95-5-21 Fuse "E" Inoperative - ABS Light On - Back-Up Lamps Inoperative - Daytime running lamps Inoperative (in Canadian Broncos) - MIL (CEL) On - Speedometer Inoperative
LIGHT TRUCK: 1992-1995 BRONCO, F-150-350 SERIES
ISSUE: On some vehicles the HO2S (miesk5 note, this the oxygen sensor) wires in the 12A690 (subassembly of the 14B060 battery cable) harness may become chafed and the vehicle could exhibit any one of the following conditions:
ABS light on
Speedometer inoperative
Back-up lamps inoperative
Daytime running lamps inoperative
Trailer battery charge relay inoperative
MIL on, displaying Codes: 172, 173 or 41 for HO2S failure
Inadvertent PCM Self-Test

ACTION: Replace the damaged wire harness and HO2S sensor. Refer to the following procedure for service details.
SERVICE PROCEDURE:
1. Disconnect negative battery cable.
2. Disconnect the solenoid terminal and positive battery cable from the starter.
3. Pull the cable downward to inspect the 12A690 harness for chafing, pinholes, etc. If necessary, remove the convolute and tape from the 12A690 harness located next to the lower RH side engine mount.
4. If the 12A690 harness is damaged, replace the 14B060 assembly (F5TZ-14300-EA) and the HO2S sensor (F4UZ-9F472-A).
5. Inspect Fuse "E" and replace if necessary (D9ZZ-14526-D).
6. Clear all codes stored in memory.
7. Retest and verify the concern has been resolved.

PART NUMBER - PART NAME
D9ZZ-14526-D Fuse - 15 Amp
F5TZ-14300-EA Harness Assembly

F4UZ-9F472-A HO2S Sensor
In attached diagram;View attachment 212176
View attachment 31273
Item Part Number Description
1 11450 Starter Motor Relay Assembly
2 N803991-S36 *****
3 14A396 Cap
4 381561-S36 Nut and Washer Assembly
5 14B060 Cable Assembly
6 Starter Solenoid Heat Shield 5.0L/5.8L Only (Part of 11002)
7 382747-S36 ***** and Washer Assembly
8 N805403-S100 Nut and Washer Assembly
9 11N087 Cover — Starter Solenoid (Red)
10 56558-S Bolt
11 34943-S36 Star Washer
12 14301 To Engine Ground
13 12A690 Wire Assembly
14 11002 Starter Motor
15 To Heated Oxygen Sensor for 5.0L/5.8L Under 8500, 5.8L over 8500 and 7.5L F-450
16 N621906-S36 Nut
17 N806925-S36MG Stud
18 12A581 Body Grounds
19 14301 Chassis Ground
20 — For Continuation Refer to Fender Apron, Right, Gasoline Engines Illustration Shown Previously in this Section
21 To Heated Oxygen Sensor for 5.0L/5.8L Under 8500, 7.5L F-450
22 12A690 Wiring Assembly For 5.8L Bronco
23 N802777-S36 Bolt for 14301 Frame Ground
24 9S286 Existing Gas Vapor Tube
25 10655 Battery
26 33799-S2 Nut (Auto Transmission)
27 5A212 Exhaust Pipe
A — Tighten to 7-9 Nm (62-80 Lb-In)
B — Tighten to 21-29 Nm (15-21 Lb-Ft)
C — Tighten to 10-14 Nm (7-10 Lb-Ft)
D — Tighten to 25.5-34.5 Nm (19-25 Lb-Ft)
E — Tighten to 9-12 Nm (80-106 Lb-In)
F — Tighten to 11-16 Nm (8-12 Lb-Ft)

@miesk5 just trying to get as much feedback as possible. It's likley I have two issues but I will start with getting the wiring set up properly then address 12A690 Wire Assembly. On quick inspection yesterday, it looked dry and clean but I'll need to pull the assembly down and remove the jacket to make sure. Probably will swap the O2 sensor regardless.

 

[ohmsm39]

Being a 95, it doesn't go back to the console like a 96 does. Your Lb\Or wire changes to black a splice s103 and grounds at G 100. You need to run the Lb\Or wire inside and connect it to Dark blue\White on the 99 harness.
Hope that helps
Cheers

@L\Bronco just following up, your info got my electrical problem solved. Thanks! No more blown fuses. Now I just have to get the temperature to display the correct outside temp. Its currently displaying 50 degrees hotter. Pretty sure I need to splice in the new sensor type that is found on Explorers.

 

[L\Bronco]

@L\Bronco just following up, your info got my electrical problem solved. Thanks! No more blown fuses. Now I just have to get the temperature to display the correct outside temp. Its currently displaying 50 degrees hotter. Pretty sure I need to splice in the new sensor type that is found on Explorers.
View attachment 31302

Glad to hear that!
Thanks for the reply! (Its always nice to know that you won the battle)
Pretty sure you are correct on the sensor, (I'm pretty sure they changed the resistance value on the newer ones)
Cheers