2005 International 4300 Electrical gremlin

Bearhead · 2025-01-27T15:44:21.000Z

Have an '05 Non-Maxxforce 4300 with DT466. Was driving to park in the shop and it died completely, check elec sys on cluster. No crank etc. newer batteries. I went through all the obvious wiring connectors/grounds and battery connections searching for possible issues, but all good. Removed the BCM and peeked inside but nothing obvious. If I leave batteries hooked up and key out of ignition, it acts weird, headlights turn on, radio on etc. Cluster will sometimes stay lit with key out. I dont have a scanner and the local dealer has been less than stellar in troubleshooting before with another issue. Any input is appreciated.

Started by BearheadJan 27, 202522 replies

BearheadNew MemberFeb 5, 2025#21
I pulled the loom out for the BCM and ABS, found one chafe through on connector, not sure if it was shorting. Repaired that and a few other areas. Waiting on split loom to arrive before I reinstall. Hope is what we have
Welder DaveExpertFeb 6, 2025#22
I'm curious how they mass produce wiring harnesses? Must have jigs and specialized machines. Can't imagine trying to manually recreate a harness.
BearheadNew MemberAug 6, 2026#23
A bit of a delayed feedback, I got the truck running shortly after our threads and its been running 100%. I had replaced all x3 batteries and all the main power cables and grounds/connectors. All codes are gone etc. The chafes in the engine harness I repaired as well. The dealer came out again and quoted $9k to replace various harnesses etc and did not guarantee a fix. I'm in it for under $1000 and that includes the x3 new group 31's. Thanks belatedly for all the help.

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