I am changing the front brake pads on my 84 300D and found that the wire going to the brake pad sensor unit mounted on the caliper assembly has broken off. I was going to price a new unit with wire but then considered splicing the wire back together. I believe there are sheaths that can be put over a splice and heat shrunk. I have never done this before. Does anyone have any experience with repairing this wire?

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
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i assume you are talking about the wire coming from the fender well down to the actual wear sensors. if so, it would be ok to splice it. i would probably heat shrink it to keep water out

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Yes, that is the wire. I think I have enough wire coming out of the box mounted on the calipers to work with.

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

is it one single wire?

I think theres two.

Heatshrink each one before you shrink them together. Don't forget to put it on before tinning your wires together.

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There are two wires, I just replaced the entire sensor harness.

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83 SD

84 CD

Was it difficult to thread back up into the engine compartment? And where does it connect?

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

Not difficult. I did 'em on the SD, but here are pics of my 123.
The two wires fit into the clip I'm pointing too, you'll need to get access to it, you'll be able to see how to open the plastic case, remove the old wires, put in the new ones. Make a note of which color wire goes where.
Pic 1 on the right, it pushes up through the fender.
Pic 2 the clip you need to get to.
Pic 3 the passenger side clip.

Attached Thumbnails

     

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83 SD

84 CD

This is really helpful. I had visions of having to get all the way to the instrument cluster.

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

The engineers did a good job here, it is a replaceable item.

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83 SD

84 CD

Did you splice this wire after all the responses. If so how did it work out. Pack Rat got to one of mine and I really don't want a new one for 45 bones. If a spice works I'm on it. Thanks

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83 300D 227,xxx miles, sold
86 300 SDL 130,000 miles, sold

After looking again at the unit I concluded that I would not be able to do a splice, as I have at best 1/4" of wire coming out of the harness, and what is coming out is brittle. I don't think there is enough wire there for a sheath to grab onto effectively. I ordered a new harness and am hoping to find the time this weekend to put the whole thing back together.

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

Well bummer. I have plenty of wire but it looks like the wire is made up like old TV coax cable, a wire then insulation then a grounding mesh band and then insulation. I didn't have a light and didn't pull the tire so I could be completely wrong. If its just two wires I can handle that. Thanks

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83 300D 227,xxx miles, sold
86 300 SDL 130,000 miles, sold

Hmmm! I'll have to cut a piece of the old dangling wire and take a look at it.

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

I don't have the old parts anymore, but don't think that's the case, just two regular normal wires.

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83 SD

84 CD