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This is Why Load Testing Electrical Circuits is so Important!

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In this video we diagnose an unresponsive vehicle security module on a 2004 F-150. Key fobs, lock unlock functions and auto headlamps all were no longer working and the fix may surprise you!
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5 сен 2024

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Комментарии : 280

@carsurvivalist 2 года назад

LOAD testing is a hot topic these days. Thank you for actually explaining how to perform diagnostic tests.

@randallmunson9909 2 года назад

@Alex-px2mb 2 года назад

You do this right, Brian. My dad's an electrical engineer and used to own and work on IBM mainframe computers as a CE for IBM. I showed him this video because he's actually working on another car and he said: "Yeah, that's how you have to do it. Swapping parts will kill the customer and you might not find the real problem." Great work as usual.

@rickacton7540 Год назад

what does your fathers mainframe career have to do with not using the parts cannon....?

@jerryrounds8586 2 года назад

This is why people from all over the country travel to this shop for repairs. Great video.

@davestewart9146 2 года назад

Technology is cool when it works but there’s something to be said about my old 77 f150 4x4 with manual windows and door locks, awesome video Brian 👍😁

@calholli 2 года назад

I feel the same... I can't wait until they come out with a super basic electric car, but with manual windows and locks.. manual everything, except the accelerator.

@jimmyconn7314 9 месяцев назад

As a mobile mechanic this video once again is so very helpfull,and time/cost saving.ty for your expertise sir

@MrBinmonkeys 2 года назад

Your apprentice just became wiser with electrical diagnosis by watching this than I was after 6 years in the trade.

@Internutt2023 2 года назад

An old 55W/60W sealed beam low/high beam bulb can make a good load tester/continuity indicator and current limiting device too (most old school mechanics probably have a spare one somewhere). Good detailed explanation on troubleshooting this issue!

@bobbyedds9554 2 года назад

An old sealed beam is my go to for testing fuel pump circuits.

@Viper81766 Год назад

Definitely

@karlwithak2687 2 года назад

Very good way of demonstrating load testing ! I sent this to my son . I was impressed the youngster noted the 11.5 volts which led into the load testing lesson . Very awesome teaching here!

@nidnar60 2 года назад

It's sad, but 90 to 95% of the mechanics along with the service writers that I know and have worked with would have gone the easy route, causing the customer more time and money just to get more on their pay check. Great Video!

@jcvinaja5542 2 года назад

I've bumped into an issue where the TCM (transmission control module) was declared bad based on codes we got. The new 10 speed transmission slammed hard into gear and wrench light came on. We decided to do a load test. We later found a wire that powers the module to be making contact on the chassis. Cut and replace that part of damage wire. Taped it good. Navigator shifted great like nothing was wrong. Its time consuming but worth doing.

@advorsky1 2 года назад

Not only are you a damn good technician but you actually give a shit and care about your customers! That is why I sent my son to you when he was living close to your shop with his 2018 Ford F-150 just to have the transmission fluid changed but other than doing it ourselves we know that bringing his vehicle to you was the same if not better than doing the work ourself! Thank you for sharing information about Fords! Even though my older brother is VP at General Motors my other brother and I and my three kids we all own Ford products because they’re far superior to General Motors Junk!

@JasonWW2000 2 года назад

To be fair, every manufacturer is capable of building junk.

@adrianmack3 Год назад

Ford has the highest number of recalls due to building junk and leaving the customer to quality test the product.

@rjinnh3933 2 года назад

If you can wade through this longish post, here goes. Had the same problem in my 2000 Expedition but without the rust. Green wire with yellow stripe in a bundle running down to the floor on driver's side to power the box under the driver's seat that provided 'Power Seat' adjustments and some other functions. The wire was on the outside of the twisted bundle where there was no tape wrap to protect it and it rubbed up/down on the edge of a Pinch Weld. The up/down rubbing, from normal driving, wore through the insulation and the wire. The exposed wire ends corroded and turned green leaving just a high resistance green powder behind. Luckily I had bought a full set of 'Moderately Used' maintenance docs on Ebay and was able to ID the box, pinouts and To/From wire routing. As I was separating the green/yellow wire from the bundle, I saw discoloration on the wire, opened the insulation and the wire was corroded back 3/4 inch from both ends. An easy fix just like Brian did. Snip/Snip, Crimp/Crimp. In 2015 I bought this 190K 5.4 2V Expy for $500 with '$500/Will Not Start' painted on the windshield. A few weeks later I replaced the 'In Tank Fuel Pump' motor and it ran just fine. I have fixed many of the problems in this vehicle that Brian has presented on UToob except a Timing Job. I'll start that in a few weeks with a Melling Timming Set/Oil Pump, Ford Water Pump, 7 Cal Van Inserts, 2 each O2 Sensors, driver's side exhaust manifold and Radiator Support. Hope to be done by Thanksgiving. HaHa.... I just couldnt resist adding this longish post to show that I had a 99% duplication of Brien's vid but going back 7 years. I have saved every one of Brian's UToob video posts. I'd love to see them all on an Indexed DVD. Brian should be able to sell thousands of them for $25 each. Seriously..... Brian is a National Asset. His presentations are Pich Perfect and he cuts to the meat of the problem without extraneous BS. I've been following him for years and should look thru my UToob Libs to see when I started saving him. Because of Brian, there are many Ford Trucks/SUVs on the road today instead of sitting in a Bone Yard waiting for the Crusher. I'm confident that my Timing Job will work out Just Fine because of Brian. BTW: I'll be using a Melling Timing Set, Oil Pump and FelPro gaskets. Ford prices are Ridicules. That's my story and I'm stickin to it........

@mikechiodetti4482 2 года назад

Load testing is the best. Use a headlight bulb(s) with a load close to 30 amps gives you plenty of light for working in the area however, the wiper motor is a nice touch. Plus gently holding the gear varies the load which can be helpful also. Nice fix Brian.

@VinniePepperoni 2 года назад

Great video, would love to see your excellent diagnostics and repairs include how you put the wire back that you cut at the module and the one you fixed at the rust spot because there are many techs that really drop the ball on those wire reconnects and many could take a real pro instruction from you to do it 100% correct

@jonclark1288 2 года назад

I always say that testing wiring is a lot like testing plumbing: If you've just fixed a plumbing leak, you turn the water back on and check to make sure the leak is gone. And if the pipe normally has about 50 psi of water pressure, you'd want to pressurize it to 50 psi when checking for leaks. You wouldn't put only 5 psi in it and assume it's good because it's not leaking at 5 psi. It could very well start leaking once the pressure increases to 50 psi. It's the same thing with wiring: If a wire normally carries 20 amps for example, you need to test it by trying to put about 20 amps of current through it. You can't put only 0.005 amps through the wire and assume it's good!

@rodcarpenter849 2 года назад

The best video on load testing circuits. It takes some time but can save car owners a ton of money. Wish all mechanics understood this

@s.j.5850 8 месяцев назад

Great tips on load testing a circuit to see if it can power the circuit. Don't try to hang off the side of a building with that gauge of wire though! Keep these excellent videos coming.

@stevec5657 2 года назад

That's an awesome lesson that can be applied to almost every vehicle out there, thanks!

@mikekokomomike 2 года назад

voltmeter readings can be misleading without a load applied. I can get a voltmeter to read above 12 volts with some hearing aid batteries in series but they sure won't start a car.

@alb12345672 2 года назад

@@mikekokomomike You can also take a voltage reading across the wire when load is applied. The wire will act like a resistor, and create a voltage drop. Ideally a wire should have zero volts across it (maybe .1 at most). If you see 2-3 volts, that is being consumed by the wire (or poor connection). I always do that when I check a charging system.

@mikekokomomike 2 года назад

@@alb12345672 right on

@alphaomega8373 2 года назад

@@mikekokomomike Learn that lesson, thinking that all I needed was a volt meter, to test my AA batteries.

@Mr2004MCSS 2 года назад

Nice job. I cut off several of the light bulb harnesses out of our junk 93 Cavalier out in the field and made some test lights that I use for load testing circuits. They work well. I measured the amp draw of each so I know how much they draw.

@MrSpeedyCrane 2 года назад

Thanks for showing everyone how do things the right way. I think it's awesome that you're teaching your son how to be an Awesome Master Mechanic like yourself. Learn everything you can from your Dad he's the best honest Mechanic out there! As always thanks for sharing Brian!!

@Don14320 2 года назад

loved the way you approached the issue, you are showing how us to look outside the pass fail status and to see and find the root cause.

@edman1015 2 года назад

Another GREAT JOB FordTech. You were born for this kind of work. You have found your gift. God is good.

@kato223 2 года назад

Great diagnostics! I had one in the past where I thought it was the computer module. Luckily I was getting them for cheap from a wrecking yard, but the issue was very similar. What happened was the cover to the wires cracked and went away on the back of the engine. The exhaust manifold was right there and the wires started bouncing off the manifold. The wire cover melted exposing the copper inside and when I would go up a hill or accelerate over a certain amount, the wire would short out on the exhaust manifold and kill the engine right then and there. It was annoying as all get out. Thanks again for a great diagnostics!

@geraldcadyii5772 2 года назад

You can see the wire diameter is swelled up at that point. If I see any other wires swelled up, failing or not, just patch/splice that area before it goes bad.

@williamalexander1743 2 года назад

You are absolutely correct about the swelling. When iron turns to rust I think it expands 10 times the volume! I'm not sure of how much copper or aluminum expands however I know that it does.

@headshot8888 2 года назад

I just took a look at the same rust pit on my 05 King Ranch. I've got holes rusted through below the wire bundle. No damaged wires. It's rusting through from below. Likely from Salty tire spray as I just repaired the left side which was worse. So much for all those years of oil spray.

@richard1835 2 года назад

This Auto Electrical diagnostic video is definitely worth watching again. Thank you FordTechMakuloco

@waqasazmat81 5 месяцев назад

Thanks for educating us on the load testing!

@terryharvey4811 2 года назад

Would have been disappointed had you not cleaned up that body ground while you were in there. I remember all the ohm testing the trouble trees had us do when ecms first hit the market. 9 volt battery powered ohm meter would give proper ohm reading but I found out the hard way {many wasted hours} that a load test would show a compromised wire in a heart beat, saving loads of diag time. We need to keep this in mind, as ohm meters will sometimes lie.Thanks for helping spread the word.

@tbirdguy76 2 года назад

good to see people going the extra mile and actually doing the diagnostic work needed instead of just turning a quick buck; how many other shops would have swapped PCM and sent them on the way,

@mohawkmike142 Год назад

Great repair along with the diag. Top notch Ford guy right there. Thx for the video.

@lisaa.powell3634 11 месяцев назад

Excellant troubleshooting skills! Thanks for showing the schematics as well as the pinout on connectors. You helpedme years ago fix 2 of the joints in the passenger rail by the fuse box. If i remember it was due to cholride in the tape that was used. I purchased the Ford splicing kit. So far mirrors and seats still work. Thank you Brian. Your son is very fortunate to be able to learn from a master mechanic.

@vicpetrishak7705 8 месяцев назад

3M Scotchkote fd manufacturers this coating for underground splices , it works well ! Great for trailer wiring .

@rays7437 2 года назад

Nice video. This is hard to explain to a customer. Sometimes finding the real problem is very time consuming and the customer doesn't understand why. Now I can just have them watch this video. 🙂 Out West we don't see many corrosion problems, it's usually added on equipment that has been hacked in.

@jimtheobald1141 2 года назад

That’s because you may live in a salt free state. Here in MN it’s terrible

@dirtfireservices Год назад

That's why u have to know how to use a multi meter and perform diagnosis correctly. So many modules get replaced by incompetent techs. Great job on explaining everything.

@dangerdavefreestyle Год назад

Proper diagnosis is what its all about. A tool that helps with that is worth its weight in gold.

@vinces8974 2 года назад

What a great teaching video, Thank you so much

@TonicofSonic 2 года назад

This motivates me to be proactive in protecting those wires anywhere I see risk of damage.

@TonicofSonic 2 года назад

Sure enough, mine had the same situation playing out. I even found a couple small holes directly below the wires where the cab rusted through. I managed to wrap the exposed wires which had not rubbed through yet with several rounds of tesa tape, then hit the holes with a metal body panel patch, threw some silicone gasket maker over that, then went over the top of it all with gorilla tape. 💪 Once that dries I am gonna go back and seal the bottom with either this liquid metal stuff I have or just more silicone gasket maker to make sure water will not get inside. Not trying to get crazy with bondo, the room is tight and the truck is old so good enough is good enough.

@samholdsworth420 2 года назад

So glad I live in San Diego and my 23 year old Chevy S10 Blazer doesn't have a lick of rust. The crusty wires in this truck definitely would not have made it with a salt bath

@TonicofSonic 2 года назад

@@samholdsworth420 I will never buy a used vehicle with rust again. The rusty vehicles in the rust belt markets sell for the same prices as no rust vehicles in other markets.

@Markomyt1 Год назад

Great work Sir! I learned a similar lesson from the wiring loom coming through the door to the body. Several wires broke from the constant flexing.

@richardthomas1743 2 года назад

Thank you for the excellent explanation and demonstration of a wire load text !

@wonjat5 2 года назад

A really good illustration of how to carry out basic testing of power and ground circuits.

@stephenmoxley3004 2 года назад

Another great diagnostic case study, Brian. I guess, living in the Midwest, you have to deal with lots of rust and corrosion issues causing all kinds of problems. Keep up the great work.

@mikehenry4743 2 года назад

I like how he said multiple times "this vehicle is very old," heck I still drive around my '69 Bronco and '74 High Boy.

@craigwiess1656 2 года назад

Few months ago was trouble shooting my 2006 E350 shuttlebus. No brake lights and shifter interlock kept it in park, everything else was functioning. Checked fuses ,brake light switch light bulbs all the basic stuff. Ended up tearing out most of the rear wiring to get rid the coach builders screwed up wiring of crimp connections and very few grounds. I ran new wire from just under the door keeping it all inside instead of the factory Ford going along the frame. Have had problems with corrosion on other E series. Tracing down other wiring specific to the coach builder was a PIA. Did buy the proper tools for tracing down short circuts, testing relays, etc..

@ReclusiveMountainMan Год назад

Great to see your son learning from the best.

@brucelott3583 2 года назад

I've been preaching this for years. I built a tester that lets me put from 2 to 12 amps on a circuit, plus direct battery connections to see if voltage drop is due to hot side or ground. It has been used a lot over the years. Good video

@watchdogu.s.a.8973 2 года назад

Would you mind sharing how you built the tester?

@anthonysova7117 2 года назад

What a great example for using load testing yes sir Brian excellent video like to add good continuity doesn’t mean good conductivity hardly ever use an old meter to test anything other than solenoid coils CHEERS AND THANKS

@kevinstrident 2 года назад

Excellent demonstration of both the though process in troubleshooting and load testing!

@neverstoplearning382 2 года назад

Corrosion and heat creates resistance. Really cool video.

@Chuck88vert 2 года назад

Your a excellent tech. I have put to use your videos. I did my timing set using your 5.4 3v videos on my 07 gt. That was 70,000 miles ago still runs great.Thanks for your work to bring use very useful videos.

@Afrattzz1 2 года назад

Excellent diagnosis Brian. Thanks for the video

@R3YNZ 2 года назад

I love these. These types of jobs are one of the most satisfying. Great work as always!

@joeG9100 2 года назад

This is a very interesting scenario. This is a really good exercise in knowing the limitations of your test equipment. The fluke meter is a laboratory grade meter. It has a very high input impedance so as not to load the circuit under test. In this situation it worked against the technician. Battery circuits are very low impedance. Hence the need for a load test.The technician was not fooled. The circuit was not open or the fluke meter would have said 0000. In fact there may only be 1 micro amp or so flowing to give the fluke such a reading. The wire was rotted and the decomposed matter was still connecting the circuit. Had we used an old analog meter for this test most likely lt would have read 0 or close. Those meters don’t have high enough input impedance to get a reading in this situation. It proves once more how analytical you have to be in order to be a great Automotive Technician.

@davidwallace3224 2 года назад

Key words not often spoken by all techs... " We're in here... do it right".

@tomfairbourn6998 2 года назад

That was impressive chasing wire is most everyone's weak point

@isaiah4510 2 года назад

Great lesson. One of the best ford techs around. Wish you lived closer to me

@ggem8125 2 года назад

I am an electronics guy for a living I found this to be a great video. Dealing with mechanics for the maintenance of a 50 vehicle fleet basic electric principles seem to be not as common a skill as you would think.

@jeffone2nv 2 года назад

Great content great fix you save the owner a lot of money 💰. Another technician 🧑‍🔧 wouldn’t have found the problem. Would have charged to replace the module. And still have the problem. Proper techniques result in a proper diagnosis. Therefore it can be fixed probably. I wish you had a shop here in Michigan.

@walcrow7319 2 года назад

The MASTER at it again. Great video and extremely helpful for when my 2014 E350 pops up with some electrical issues.

@chrisforker7487 2 года назад

Amazing video, I’d never thought about load testing. Electrical stuff is usually foreign to me.

@stevesnop3798 2 года назад

You are a beast of a technician. Love watching your vids.

@kenj.8897 Год назад

Junior there is going to have a bright future, learning from the best.

@calholli 2 года назад

You can load test with a simple headlight bulb too.. It pulls like 4 amps.

@FordTechMakuloco 2 года назад

Yes but the window motor doesn't shatter or burn you like a bulb.

@380.motorsports 2 года назад

Excellent troubleshooting as always.

@paulhudgins5120 2 года назад

Nice job, you did a great job explaining load testing & how do the diagnostic testing. Just replacing parts doesn't isn't always the fix or the answer.

@wayne-oo 2 года назад

Great job !

@richard1835 2 года назад

Thank you for a very well organized Auto Electric Diagnostic. Thumbs up

@leonciorodriguezaguilera9513 2 года назад

Getting Better All The Time Amigo Fordtechmakuloco, Excellent Video Tutorial !! Thanks a Lot For Sharing ✌🏼

@Richard-pt4ym 4 месяца назад

Go purchase a Load Pro test leads. I own a pair and they work great for load testing any DC Circuit. I used to be a Heavy Equipment Mechanic, but now retired.

@FordTechMakuloco 4 месяца назад

I will never own a power probe product.

@FC-cz6zd 2 года назад

Great video. I wish I could understand the process better. Some reason I have a real disconnect with this kind of stuff. Regardless, my 02 f150 has a whole bunch of GTE silicone sealant due to water intrusion frying the GEM module (started acting possessed) about 10 years in and other areas as well. Been a great truck but Ford really dropped the ball for a long time not sealing up their 150s very well.

@hustlehard4063 2 года назад

I recommend you consider replacing your windshield, I've dealt with several f150 f250 that leaked due to a bad seal. It's hard to pull the windshield and reseal it unless you get a professional

@FC-cz6zd 2 года назад

@@hustlehard4063 had that done just before replacing the GEM module. The upper left of the factory shield was notorious for leaking and frying the GEM.

@mrdanomac7937 2 года назад

I understand the methodology but suck at explaining things, but I'll try. The easiest way to think of load testing in this manner is to think of flow. Most understand that if you replace a 3" or 4" toilet drain with a 1/2" drain pipe you don't have enough flow and the toilet will back up/not work correctly. So what load testing does is it checks to see how much flow capacity the wire is capable of handling. Multimeters use very little of this flow to work which is why it looks OK, until they tried flushing the proverbial toilet (in this case - connecting up the window motor that requires a lot of flow.)

@FC-cz6zd 2 года назад

@@mrdanomac7937 Thanks! I was just mentioning to my wife yesterday it would be nice to upgrade our toilets.

@mattcat231 2 года назад

@@mrdanomac7937 I like the toilet analogy, here's another way to explain it using a toilet. Toilets have water jets all around under the rim, each jet represents 1 strand of copper wire. Flush the toilet when brand new, all the jets work beautifully, like new wire, all strands connected gives you the strongest current. Now, the toilet is 20 years old, and you have hard water deposit issues at your house, you flush it, and only 1 or 2 jets release water, the toilet is not going to flush, now take the wire and add corrosion (hard water deposits), you may have 1 or 2 strands still connected, but it won't carry a load.

@Roudter 2 года назад

Brilliant. Diagnosis is an art. Thanks.

@jasondoolin6476 2 года назад

“Intergalactic national backorder” 😂

@davedeatherage4902 2 года назад

Thank you sir for the expert advice, I will take you're tips, great one's for a learning Diy'er like myself.👍🏻🇺🇲

@michaelparra8719 2 года назад

a h7 bulb also works good.

@stevew3155 2 года назад

@FordTechMakuloco Tip: Next time, relocate the ground higher up on the kick panel so it takes longer for the advancing cancer (body rot) to reach it causing a completely different set of problems and a return visit/repair. Good job identifying the actual fault (corroded wire inside the insulation) and the underlying cause (wiring insulation rubbing against rough corroded surface)! Once the ground fails, you'll see weird co-dependencies such as things work until the blower motor is turned on or the like. Wait till you get one where the engine runs just fine until you step on the brakes!

@FordTechMakuloco 2 года назад

Yup we had one where you put the turn signal on and he engine stalls. Been there done that. This ground will be just fine for the life of the truck.

@LudekNesnidal 2 года назад

WOW I am learning lots of from you! Thanks for your videos. You are true professional. 👍

@killersaint89 2 года назад

Posted this just in time for me to dive into the flex fuel circuits on my 99 ranger, the inside kick panel by the drivers footwell looks about the same as this truck, I suspect it's a similar issue.

@tom73055 2 года назад

I’m wondering why there is moisture and rust on the inside of this ford in the first place . Great video as always ,thank you

@FordTechMakuloco 2 года назад

Water leak from a body seal or wiper cowl.

@cheapers1952 2 года назад

Well this is a condensed version It looks to Me to be priced at around $300.00 + (mostly for the knowledge) I can guarantee that that customer would have spent tripple that from more than one shop !!(with guess work)

@roberthickoxjr 2 года назад

Thank you from the bottom of my heart. Great troubleshooting info.

@Twobarpsi 2 года назад

Best Tech on the planet!!

@jwelchon2416 2 года назад

WOW!! That's some powerful diagnostic work!

@phillock7944 Год назад

Well done matey, excellent explanation.

@jerradguillory7909 Год назад

Great video man!!! Great explanation when i work on my customers fords you always seem to have some good info i can use for those f word headaches 🧐😂

@agoodneighborautorepair2176 2 года назад

👋SIR, LOAD test the king of the test, very nice explanation. Blessings

@salvadorgutierrezr5914 2 года назад

Thank you for teaching 🙏 great video ✌️

@woodymiller3895 2 года назад

Good ol Ford, body seam leaks just like the failing gem module under the A piller to cowl.

@ronaldsinclair6837 2 года назад

Enjoyed your style of diagnosis.

@kingjames8283 2 года назад

I'm dealing with this same issue with the ABS module on my semi-truck. Every time I hit a bump in the road, the module emits several chirps to tell me it is loosing contact. The ABS self test already tells me the issue is with the wire feeding wheel-end number four which I have checked and confirmed is good at the wheel sensor. So between where the ABS harness comes out of the truck cab and going back to second drive axle, there is a sensor wire that is compromised. Why I haven't yet addressed it is because that section of harness is inside the frame rail which is buried behind the fuel tank, air tanks, and transmission and there is no room for me to access the frame harness. I suspect a broken wire or a chaffed wire that is grounding out against the frame rail and to fix it requires removal of all the air tanks and left side fuel tank which is a major job. Sometimes I just hate wiring.

@fatchanceb1823 2 года назад

Same with a simple continuity test. Most multi meters beep under 200 ohms, if you don’t look at it when you’re ringing out a circuit, you may miss w fault in a wire or connection.

@FordTechMakuloco 2 года назад

A continuity test will pass, this is the only way to test the load carrying capability of the circuit in question.

@ovalwingnut 2 года назад

Cleverly diagnosed and wonderfully repaired. Shame the Mfg's can't do a little something extra in those "repeat areas". Liquid sensors are as cheap as chips.. placing a few in the "common hot spots" would be fantastic. Funny, I don't think this vehicle is so old.. my bad. I gave up wanting anything from the 80's+ (having lived through it as the typical shade tree mech ;) Yes, things are much better now but it's burned into my brain. Thank you for the super videos. You [are] the "Vehicle Whisperer". Cheers!