While swapping out my front struts I noticed a ground wire had been crushed by the strut bar.

Not sure how long it has been like this but last time I drove it I could here revs through the radio in the background. From looking at it, both sides of the insulation are gone but the wires itself look OK. I wrapped it up in electrical tape.

Should I take it to the dealer to replace, any idea how long it is? It is the one net to the battery.

 

 

In the photo I can see the paint color showing through the wire, which to me tells me there a a lot of broken copper strands and the wire does not have 100% conductivity anymore. Engine noise through the stereo is also a sign of a bad ground, among other things. But the two here go hand in hand. The insulation is meaning less on this ground wire because if it had none it would be touching the body which is grounded just like the wire itself and so it's null.

In my opinion this wire needs to be replaced or at least spliced and fixed. There are resources to make your own but you could also find out what part number this is and get the wire from your Ford parts counter and do it yourself if you're inclined to be able to do such a thing.

Just curious did wrapping it with insulation do anything to resolve the engine noise in the stereo?

 

Ford will charge you for a whole new engine harness they don't sell just the ground.

 

Several wires look broken and compromised. The full harness will be expensive. I would try to strip back the insulation and get a proper size splice crimp connector then shrink wrap.

 

I would shrink wrap or coat it and let it ride.

 

I would splice in a proper gauge segment to replace the damaged area, shrink-wrap it, and call it a day.

 

The correct way is to splice in some new wire, using the appropriate good quality crimp connectors, or via solder.

If you use solder (which will end up looking nicer if you use some shrink wrap over the splice), you'll need a pretty heavy duty gun or propane torch for that gauge wire, just FYI.

 

Where can I get a splice that thick?

 

Go to a local car audio shop. They should have a bin of scrap wire. They might even take care of it for you too...

 

You need to determine the gauge wire. Do a search for wire splice crimp or connector. Many high end car stereo install shops that need heavy wire situations for high powered amplifiers might be a help. Here is an example for 2/0. Your going to need the right tool also. Maybe contacting a good electrician.
https://m.mscdirect.com/mobileweb/pr...tedParts=false