Today I replaced the rear differential speed sensor in order to keep the odometer from intermittently dropping out.
While I had inspected the sensor wiring just last year and did NOT find any obvious problems with it, and even though it still appeared to be in good working condition even now, due to the occasional random but repeated odometer drop outs while driving, I decided that I just needed to replace it with the Standard Motor Products S824 connector pigtail which I already had on the shelf.
During the replacement/repair process, I was able to find the actual HIDDEN wiring problem ... which, of course, was wire fatigue UNDERNEATH the wire insulation, leading to the intermittent bad connection.
I am not sure why I missed that last year, as the same thing happens to wiring going to ALL the doors in my Dodge truck !!!
First picture below shows how one wire is stiff from fatigue while the other one is soft and easily bendable with minimal effort while still having ZERO signs of damage on the outside. In short (electrical pun intended), the copper wire was already broken despite the insulation still holding it together and appearing flawless.
IMPORTANT NOTE: It is actually MUCH easier to FEEL these wire fatigue problems then to SEE them!!!
Second picture below confirms the one already broken wire, as it easily came apart at that spot only by pulling on it ... even though its light gauge wire and Im strong, Im not THAT strong.
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