How Electrical Corrosion Causes Wiring Problems


Electrical corrosion can cause voltage and current flow degradation which sensors may report as a system fault. If cables are not replaced when corrosion is present, it can lead to fires and further electrical breakdown. The day may yet come when trucks no longer have  hood latches and problems will be solved by the manufacturers only. Until then, though, auto electrical mechanics will still have electrical problems to repair: corroded wires and connectors, bad sensors, lighting problems and emission system problems.

A lot of corrosion problems arise when there is poor quality wire insulation present. It’s very common to see spots along harnesses worn through the insulation on trucks less than two years old. Once the wire is exposed, wicking starts and systems start failing. The wiring itself on a lot of trucks leaves a lot to be desired too. Wires are usually not thick enough and their internal tensile strength is lacking. The reason for the use of sub-optimum wiring components is usually cost-related. Truck drivers prefer a more affordable vehicle, despite the fact that cheaper trucks employ low quality wiring that corrodes and requires expensive maintenance.

The uptake on a premium wiring module for a truck engine is only about ten per cent more expensive than a subpar wiring module that may break down. It’s worth considering paying slightly more for a wiring module because it will last longer and save you money on maintenance when corrosion happens. Another alternative drivers have is to place their wires in piping to make sure they don’t get wet or covered in oil and grease.

Top Three Tips To Deal With Corrosion

  • Don’t ever use a test light with a piercing probe. Those poke holes in the wire that open up a gateway for moisture. Once wire is wet, corrosion sets in immediately.
  • Don’t use non-sealed butt connectors. These are fast and simple, but offer no protection from corrosion. Use soldered and/or crimped connections with double-walled heat-shrink tubing to seal and insulate the connection.
  • Learn how to repair electrical connectors properly. There are procedures for repairing various sealed connectors supplied by the manufacturers. Follow them. If there’s dielectric grease or some other insulator inside a connector, make sure you refill the repaired connector.

If it’s time for scheduled maintenance, call Sydney Truck Electrical today for a quick call-out and rapid diagnosis of your truck’s problems. Our mobile truck mechanic in Sydney has been operating 24 hours per day for over 20 years. Call us on 0423 286 455 to schedule your appointment with our team. We will take a look at your truck using telematics and can replace any component that is faulty.

It helps to schedule maintenance management on a regular basis. Our maintenance team can schedule a regular work order for you and your fleet. We perform corrosion checking and vibration analysis among an ever-increasing list of services. Our predictive maintenance devices converge with your truck’s sensors to provide information about faulty pieces of equipment. Trust our mobile mechanic as your preferred supplier and call today for any repairs to your trucks or trailer.