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What size gauge wire for 1996 Ford Explorer driver side power window.

Clarence38

Member
Joined
October 22, 2023
Messages
24
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City, State
Sanford
Year, Model & Trim Level
1996 Explorer Limited
I recently soldered my power window connector together and I am wanting to re-dew the wiring so it's a reliable connection. The blue wire connects to the copper wire between the orange, pink, and purple wire. I'm thinking the gauge wire is a 6 gauge but not sure and need some insight.


Ps. The windows go up and down but I rather be safe than sorry.

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It's been a while since I was in that loom but I don't recall any wires nearly as large/low as 6ga. I'd guess they were closer to 12ga or some 14ga too, BUT, windows don't run that long, so it's not going to be that much of an issue if your wire gauge is a bit on the small side but instead what it needs to be is durable enough to handle flexing back and forth every time the door is open and shut. It's mostly after the wire gets frayed apart due to that opening and closing the door, that causes a hot spot on it.

For this reason, the ideal wire to use would be very fine/high-strand-count wire which is commonly found with silicone insulation and sold for hobby purposes (among others, I mean in short lengths instead of a whole spool). That will probably flex at least 10X more before failing compared to the large strand, low strand count, wire pictured.

Regular wire will work, and is what Ford used, but that's also a large part of why it failed. Beware of copper clad aluminum wire, you definitely don't want that, can't flex many times at all before fatigue failure.

The whole circuit for all that blue/black-stripe wire feeds power to is 30A, but this is for the combination of all windows operating simultaneously and the moon roof. If you won't ever have that happening, you could get away with using 14ga but I wouldn't go smaller, and ideally 10ga to 12ga. There is no need for 6ga unless you just happened to have that lying around but as mentioned above, # of strands is going to matter more in the long run.

Here's an example, and I have no idea how they can sell it so cheap, considering it would cost me more than that for shipping alone:

 






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