ABS line cut - must replace engine wire harness?

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by newguywithpups, Feb 6, 2025.

  1. newguywithpups

    newguywithpups Junior Member

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    Recently I lent someone my car. They had to drive in snow so they put on snow chains. Whatever happened, the chains snapped and did quite some damage to the surrounding area on the front driver side.

    The most expensive damage is severing the ABS line. Dealer and local shops said I can't just patch the wire, which is shielded, and I'd have to replace the entire engine wire harness, which retails for $4000+ but I can find it for a few hundred salvaged. However, it's supposedly roughly 25 hours of labor (which I believe, being that thing looks to connect to everything - the entire fuse box is part of it), which labor itself would cost $4000+.

    Anyone happen to know if it's possible to replace just the severed lines if I have the entire replacement engine wire harness?

    The ABS is at stake here so I take it the recommendation is to do a proper replacement (at $4k+) than me practicing my soldering skills...

    (Might also mention, the wheel speed sensor was also severed, but the replacement for that seems much cheaper and I don't mind paying to just get fixed straight up.)
     
  2. rjparker

    rjparker Tu Humilde Sirviente

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    It can be done with good soldering, adhesive lined heat shrink and most of the shield coverage maintained.

    I would certainly try it. It's not like rf cable where perfect impedance at many frequencies is essential.
     
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  3. ASRDogman

    ASRDogman Senior Member

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    You could have the person who didn’t put the chain on correctly pay for it.

     
  4. newguywithpups

    newguywithpups Junior Member

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    I don't know for sure whether they put the chains on incorrectly. The chains were unused, I myself had never put on and used chains before. To my knowledge I purchased chains correctly sized for the stock size tires on my car. For all I know, the same thing could have happened to me. The person said they followed the directions that came with the chains. I'm not saying for sure they didn't do anything wrong but they're a family member and I don't think they were being reckless or negligent or hiding anything. We're still open to discussing who pays for what, but meanwhile I'd like to avoid anyone selling out thousands if it can be avoided.
     
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  5. ChapmanF

    ChapmanF Senior Member

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    The brake ECU has a sensor test mode you can enter with a command from a scan tool. In that mode it gives much more persnickety error codes about the speed sensors. If you use that after a driveway repair, and pass, you're probably good.
     
  6. newguywithpups

    newguywithpups Junior Member

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    This would be from a normal OBD scanner, or Dr. Prius, or that software thing that runs on Windows 7 (forgot what it's called) - I have access to all.
     
  7. frodoz737

    frodoz737 Top Wrench

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    Raychem makes shielded wire splices that are two part. An environmental for the core and a shielded sleeve for the outside. I have used three different sizes for single, twisted pair and triple twisted shielded wire.

    [​IMG]
     
  8. rjparker

    rjparker Tu Humilde Sirviente

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    I would get a junkyard front speed sensor cable as long as reasonably possible and splice it in such that the spliced part was not flexing.



    This is exactly how I would do it but I would lay as much of the shield material over the slice and solder it as well.

    IMG_7373.jpeg

    A proper repair would simply work with no codes, nothing special needed.

    fyi, the back sensors have extra inline connectors, go much further and have no issues.
     
  9. newguywithpups

    newguywithpups Junior Member

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    Thanks everyone! What I'm hearing is "it's actually possible to splice shielded cable, so do that".
    I already ordered the whole wire harness off eBay (salvaged) yesterday for less than $300 so once that gets in, I'll see if I can just cut off the whole ABS wire and splice it to the damaged wire. In hindsight I probably could've just spliced in some other shielded wire and not have bought the entire wire harness, but if I can actually get this to work, I'll just be happy to have saved the $9000+ it would've cost for the dealer or the local shop to fix this.
     
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  10. frodoz737

    frodoz737 Top Wrench

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    One thing to keep in mind. Low voltage communication wiring is more susceptible to poor quality repairs and interference. With shielded wire the repair is critical and the shielding must receive the same care as the center conductor/s. An LCR meter is your best friend in this situation. Good luck.
     
  11. rjparker

    rjparker Tu Humilde Sirviente

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  12. newguywithpups

    newguywithpups Junior Member

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    It's not just the speed sensor though - it's apparently some additional wire that's part of the main engine wire harness. ABS sensor I believe, but I don't know for sure since I don't know what parts are what. If it was just the speed sensor, I would just replace it completely as that job was quoted much less.
     
  13. ChapmanF

    ChapmanF Senior Member

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    Sounds as if what got cut was the shielded wire run that is part of the main harness and connects the easily-replaced speed-sensor cable to the skid ECU.
     
  14. rjparker

    rjparker Tu Humilde Sirviente

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    Yes Toyota calls the circuit a speed sensor which is also the abs sensor.

    The same sensor is used to calculate vehicle speed and used for abs and traction control purposes.
     
  15. Mendel Leisk

    Mendel Leisk Senior Member

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    No harm in just trying to repair the break. If you can get that shielding, as an experiment, and if it's possible: leave it pushed away from the repair zone for a few days, to see if anything complains.
     
  16. newguywithpups

    newguywithpups Junior Member

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    I haven't even tried taking a close look at the damage so I'm coming in to this with zero idea of what's in there (and sorry I don't know how to read the diagram you included earlier), but it sounds like ABS/speed sensor is one and the same, which is connected via its own wire (the one you posted pics of) - and that wire is connected to a branch coming from the engine wire harness (assuming the mechanics are right about damage to the engine wire harness)?

    As in, it's multiple components connected in series that are damaged - but they all lead to one ABS/speed sensor - as opposed to a speed sensor and wire being damaged, and some other ABS component/wire in parallel that also got damaged?

    (These are the two electrical part numbers/links the dealership said I needed to replace - engine wire harness, speed sensor. I already ordered both for much cheaper salvaged off eBay.)
     
  17. frodoz737

    frodoz737 Top Wrench

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    Good thing about repairing cars is when they break...you just call a tow truck. Some of us don't get that option. ;)

    Best wishes @newguywithpups
     
  18. newguywithpups

    newguywithpups Junior Member

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    The dealer actually sent a short video - attached a couple stills. Now that I've watched a YT video on replacing the speed sensor, I now recognize one of the stills featuring a completely severed wire that I'm pretty confident is the speed sensor wire.

    The other still features what I'm guessing is part of the engine wire harness. The jacket has been chewed through but it's hard to tell what damage has been done to the actual wires. The shot was taken from next to the tire, facing forward. It's clearly separate from the speed sensor and I have no idea where those wires go (based on the video/still - I haven't tried following the wire in real life).
     

    Attached Files:

  19. rjparker

    rjparker Tu Humilde Sirviente

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    If you are going to do this yourself you need to define the wires involved. The first thing to do is jack up the car, remove the tire, light up the area well and take some good pics. Both close and at a distance to provide perspective.

    IMG_7381.jpeg

    The purpose of the wheel speed sensor:

    IMG_7382.jpeg
     
    #19 rjparker, Feb 7, 2025 at 7:56 PM
    Last edited: Feb 7, 2025 at 9:26 PM
  20. rjparker

    rjparker Tu Humilde Sirviente

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    You need to get clear well lite pics of this area. My guess it the wheel liner is gone and these are two cables merging into one probably partially from the engine fuse box.

    IMG_7383.jpeg

    Not impossible to fix even if some wires are exposed or cut but is more challenging than the speed sensor wire which is likely plug and play.
     
    #20 rjparker, Feb 8, 2025 at 11:43 AM
    Last edited: Feb 8, 2025 at 12:51 PM