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Bad ground connection

 
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Old 06 Jul 2018, 11:02 pm
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Default Bad ground connection

Was doing some maintenance on my PT today when for some reason (maybe my Guardian Angel tapped me on the shoulder) decided to inspect the ground connection on the right inner fender. Seven ground wires are crimped to a ring terminal which is screwed onto the inner fender. They didn't even bother to remove the paint around the screw hole. The wires had corroded to the point that they were just brown powder. The whole connection crumbled in my hand. How it even worked in violation of Ohm's Law is a mystery to me. Managed to strip back the wires and twist them together and double crimp them in an AMP butt connector. Crimped a 10 AWG wire in the other end of the butt connector and ran it up to the bracket on the right strut tower. Terminated the #10 wire with a 1/4" ring connector and grounded it at the same location as the existing ground strap on the bracket.
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Old 07 Jul 2018, 06:01 am
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Default Re: Bad ground connection

For those that don't know...

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Old 07 Jul 2018, 09:26 am
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Default Re: Bad ground connection

Lion,

Good pic of the similar situation on the left (driver) side. I had modified that situation some years ago upon replacing the cheapo stock #8 battery cables with heavier cables. Took the opportunity to eliminate the crappy sheet metal screw and replace it with a 1/4-20 stud through an existing hole in the strut tower then bonded it with a length of #10 to the battery ground stud shown to the right in your pic.

My struggle yesterday was on the right (passenger) side. There is a similar crappy sheet metal screw ground on the inner fender on that side as well. Probably should have mentioned that the upper motor mount was out which made the otherwise difficult to see connection much more visible.

Giving these type connections an occasional shot of WD-40 is a good idea. The WD-40 wicks up the wire strands and displaces any moisture as well as provide some protection.

Last edited by Carl48; 07 Jul 2018 at 09:28 am.
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Old Yesterday, 06:33 pm
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Default Re: Bad ground connection

FWIW, did some research on the right inner fender ground connection. On my 08 base NA gas PT this connection provides ground for PCM (4 wires), A/C compressor clutch, 02 sensors, radiator fan module, and back-up light switch.

Note... this will be different for other model years, diesel, trim, etc. Also, on some PTs there may be two ring terminals at this ground point.
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Old Today, 03:10 pm
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Default Re: Bad ground connection

I was tasked with a project on an industrial lift truck this week. One of the ground wires was cut away from the harness strap which was steel and very sharp. Over a period of years it cut the wire and increased the resistance, which made the computer unable to give voltage to any sensors and so the engine cranked but not run.
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