O/D wiring issue

[msasasgs]

I've had my 2005 STX for 9 years and have had the o/d switch wiring break 4 times already. Each time, the wires appear to have fatigue failure at the bottom of the shifter lever. I have replaced the section with multi-strand wire to try to alleviate this but it keeps coming back.

Ranger is my second car so I'm only doing 1000 miles a month max. It's not as if I'm working the shifter overtime!

Anyone have any ideas on this and how to fix it permanently? Thanks in advance

 

[Dirtman]

Fix the wires and put better shrink wrap and shielding on them?

 

[RonD]

There is something else wrong, something is placing a strain on the wires if its happening at the same place, maybe there is a "bur" inside the arm that is cutting the insulation when arm is moved

Maybe hit wrecking yard and replace the whole shift arm, I don't think they are Ranger specific, but may be

 

[msasasgs]

Fix the wires and put better shrink wrap and shielding on them?

Thanks @Dirtman - BTDT! Shrinked 2" of the wiring and curved it to follow the contour around the shifter base - lasted 2 months this time.

I need another beer!

 

[msasasgs]

There is something else wrong, something is placing a strain on the wires if its happening at the same place, maybe there is a "bur" inside the arm that is cutting the insulation when arm is moved

Maybe hit wrecking yard and replace the whole shift arm, I don't think they are Ranger specific, but may be

Yeah, I'll look more carefully when I pull it out again this weekend. Thanks for the input.

PS: The copper wire appears to be breaking inside the insulation without the insulation being damaged.

 

[Dirtman]

I wasn't being sarcastic... I know i always come off that way.

Have you checked the shift lever bolts at the bottom of the column, they always come loose its a known ford ranger problem. Maybe they are loose causing the shifter to jam the wires against something?

 

[Dirtman]

Another thought, the digital range sensors wear out and cause the shifter to get a little stiff so you have to put some extra muscle into moving it. Might be causing you to move the shifter hard up or down and binding the wires?

 

[msasasgs]

Another thought, the digital range sensors wear out and cause the shifter to get a little stiff so you have to put some extra muscle into moving it. Might be causing you to move the shifter hard up or down and binding the wires?

Sarcasm is like water off a duck's back .

1st point: I haven't checked those bolts but will do so this W/E.

2nd point: I haven't noticed any stiffness in the shifter action but that could be the familiarity issue again. I'll give it some attention next time I'm out on the road.

I'll take some pics and post them...

 

[pjtoledo]

and some extra wire and make a loop to spread the flex over a longer area???

 

[msasasgs]

To all those with better insight than me , my apologies for not posting feedback sooner - grey hair tends to have more of an influence these days!

@Dirtman - bolts were good. Thanks for the tip.
Problem turned out to be a total wire failure at the transition into the shift lever.
Replaced the wires, extended the loop (thx @pjtoledo) added extra shrink and it's been good.