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2-6 Electrical
Section 2: Electrical
Equipment Grounding Guidelines
• Do not ground the body to the transmission or transmission crossmember. Ground accessories
to the chassis or the vehicle battery.
• Splicing into circuitry relating to the electronic engine and/or transmission control systems is not
acceptable because of the adverse effect on the electronic system operation.
• Adequately protect electrical connections exposed to the elements.
Wire Insulation
• Polyvinyl Chloride (PVC), rated at 90°C (194°F), is the standard wire insulation that is acceptable
for inside body use, but is not acceptable for underhood/underbody wiring.
• Hypalon insulation should be used on links only (Ford Specification ESB-M1L54-A).
• Cross-linked Polyethylene (XPLPE or SXL), rated at 135°C (275°F), is the required insulation for
underhood/underbody applications (Ford Specification ESB-M1L123-A).
• GXL can be used as an alternate wire (Ford Specification ESB-M7L85B) as long as the
concentricity specifications are met. To provide a water-resistant seal in conjunction with crimp
connectors, a Duraseal crimp connector is recommended since it is designed to account for
outside wire diameter that is smaller than the present SXL wire.
Terminals and Connectors
Connector Types
• Submersible (sealed) — A connector that is capable of being immersed in water.
• Weather-resistant — A connector that will retain its sealing and connection qualities while being
exposed to adverse weather conditions.
• Duraseal crimp — A supplier trade name for a sealed wiring repair or splice.
When a connection is not defined (typical situation — harness-to-harness connectors), the
following suggestions should be implemented:
• Determine the connector type. If it will be located in a hostile environment, use a submersible
(sealed) connector; if not, use an open connector. A hostile environment is defined as being
exposed to water and/or salt accumulation and/or high temperatures (for example, underhood,
exterior panels and footwells). Use in-line connectors with secondary locks to prevent the
terminal from being pushed out.
— Do not use single wires smaller than 14-gauge in a 2-way or larger weather-resistant
connector (the very large style), since the wire may break during disengagement.
— Use Hypalon, XLPE or Elexar insulation in submersible connectors to maintain sealing
integrity. PVC is not acceptable because it cold flows and allows setting in a deformed
pattern, therefore compromising the integrity of the seal.
2010 Expedition SSV Modifiers Guide, 07/2009