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HELP!!! serious wiring problems!!!!!!

823 Views 15 Replies 6 Participants Last post by  Broke_Two_Foci
ok, so a few days ago the fuse for my tails/dash lights blew, so i got a bigger fuse cause this is the second time this happened, and i know its due to me having all 5 of my gauges power running off the same wire comming off the radio-light up harness so that when i turn the lights on then the gauge lights all turn on along with the dash lights like OEM. so last night im taking my GF home, i pull in the driveway and i go to shut the car off and take the key out, but the car was still running. so i put the key back in, then to ON, and back to OFF and took it out, still running. so im like WTF and quick pop the hood and disconnect the battery and the car dies out. so i wait a while and then hook it back up, get in to see if it will start. starts fine, so i see if it shuts off. shuts off fine......did it again just for giggles. so its running, i go to turn on the lights, no headlights, no tails. check signals, no signals, no brake lights either. all that works are hazards. WTF! so i get the GF and her mom to drive ahead of me and lead me home. peeked at fuses and that same friggen fuse is blown, and im guessing a few others cause normally when it blows only the tails dont work. so im going to take a look at it tomarrow and run the power for all the gauges on its own circuit directly from the battery with an in-line fuse and a toggle switch and put the right size fuses back in. hopefully that takes care of it but anyone got a clue what went wrong?

NEXT DAY:

ok, so today i go to work on the car and see what the hell is up.......7 or 8 fuses are blown....WTF.....fog lights, headlights, tailights, signals, rear defogger, dash illumination, etc. WTF....how so many???? so i replace all the fuses, and i re-do the wiring from my aftermarket gauges to have their own direct power from the batter with 12gauge wire with an in-line fuse and a switch, that way its not drawing extra power from the dash lighting/tail lights (same fuse). so i go to put in a new fuse for the dash/tails....blows right as im putting it in (2x the called for size), however no key in the ignition and no switches open, so theoretically no power should be going to that fuse correct? well for giggles i put the key in to check the rest of the lighting, two of the fuses previously blown blow right away as i turn the key before i even tried turning the lights on. so as of right now the three fuses flown are "light switch", "fog lamps", and another one also called "light switch" WTF!!!!!!!
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ok, heres the thing. three fuses that are blowing i took a continuity tester to, and they are grounded on both sides of the fuse with no battery in the car....this obviously makes no sense. nothing has been changed recently, just all the sudden there are this problems. fuses # 32, 44, and 61 are the three that are grounded and blowing out without switches being open. anyone have a stinkin clue WTF is wrong with my car?
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found the problem, never put a 30amp fuse in a 10amp spot


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Just wondering if you have checked your rear harness. Your problem sounds like what I had happen.

Check my sig for more info
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wow thanx ill have to check that, i bet thats the case, i ALSO drive a 2001 zx3 s2 so ill be checking that out, thanx for the info.
NEVER, EVER put a larger fuse in to "solve" a problem! it's trying to tell you something!

Mike
wow thanx ill have to check that, i bet thats the case, i ALSO drive a 2001 zx3 s2 so ill be checking that out, thanx for the info.
i drive the same year and having the same problem, but my ECU got fried, my wires look the same, do you plan on replacing the wiring harness intirely i am and was wondering if for the most part are they the same
found the problem, never put a 30amp fuse in a 10amp spot



No offense, but you answered you own question in your first post. NEVER EVER put a larger fuse in. The wireing for that perticluar fuse is only rated at a certain amperage. If the fuse is too large, you wiring becomes the fuse.... as you found out.
thanx guys
im getting the chunk of harness from a local junkyard tomarrow and im gonna replace the fried section. im also gonna check out those wires on the hatch before i go testing crap again.
I also have a 01 ZX3 S2 but this problem is not isolated to the S2's. It has happened to many people who own ZX3's.

I've lost count of how many reports....




I've asked the mods to sticky my post and to add a poll to the original thread in order to help keep count but have not got anyone to do it yet.

Check my sig to read about the problem, how I discoverd it and to see photos.

It does not require the replacement of the entire wiring harness, just a patch to the rear.



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I just went and checked the hatch on my car and same thing. thank you for pointing this out. I am in the prosses of finding out if ford is going to fix this for me or if I am fixing it my self.
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I just went and checked the hatch on my car and same thing. thank you for pointing this out. I am in the prosses of finding out if ford is going to fix this for me or if I am fixing it my self.
You will be fixing it yourself is my guess.

I've tried to bring it to Ford's attention and they don't seem to care


If you do get Ford to look at it, let us know what they say and who you talked to.
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well I just talked to my local ford service writer/focal jet member and he told me that he could not find a tsb for the rear hatch wireing.
So I will be fixing it myself. he did tell me that the way ford would have fixed it is not the way I would have.
I guess it is better this way I can take my time and properly fix each wire.
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guess what, you were right, my wires in the hatch ARE exposed, not as bad as yours but they definately are.
dont waist your time with the dealer. just clean any exposed parts and tape them tightly.
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