[RobertB]

Do people also disconnect the connector where it goes into the motor to make sure the internal contacts are also not corroded? Indicated by blue arrows in attached photo. That internal area also gets corroded and causes failure. On the latest designs Toyota now has a new internal foam washer inside the connector to motor.

Yes, the seal or lack thereof is what caused the three phase power connections to short out, not the braid. Spraying the braid and not ensuring the motor/cable connector is properly sealed does nothing as salt laden water will still get into connector terminations and corrode them. There are posts about this when the problem first reared it's ugly head back in 2021. I believe the first connector mod with the open clamshell added an improved gasket/seal but not sure.

 

[CoffeeBear]

Yes, the seal or lack thereof is what caused the three phase power connections to short out, not the braid. Spraying the braid and not ensuring the motor/cable connector is properly sealed does nothing as salt laden water will still get into connector terminations and corrode them. There are posts about this when the problem first reared it's ugly head back in 2021. I believe the first connector mod with the open clamshell added an improved gasket/seal but not sure.

I guess I thought that corrosion on that braid worked it's way up to the connector.

 

[Lagos]

This is DC voltage, it’s not 3 phase power. The braided wire you see is shielding. When that corrodes, you start to have issues with AM radio and possibly other symptoms.

 

[gregeusa]

I'm confused, this is the wire to the motor?

Then it is 3 phase AC... made up by the inverter system from the DC from the battery

(DC does not typically need shielding or make radio noise, AC does)

 

[Lagos]

I'm confused, this is the wire to the motor?

Then it is 3 phase AC... made up by the inverter system from the DC from the battery

(DC does not typically need shielding or make radio noise, AC does)

I stand corrected. You’re right.

 

[Keith_A]

3 1/2 years ago I published a post on the now famous "CableGate: issue: CableGate Post # 507 In that post I stated that I used CRC Heavy Duty Corrosion Inhibitor and Permatex Dielectric Grease. This is what the connector looks like today:

Note the 2 holes in the bottom of the orange connector cover. The next picture is the connector with the orange cover removed:

Other than the dirt, the metal braid around the 3 wires looks just like it did 3 1/2 years ago.

Please Note, the discoloration of the braid and the metal clamp around the connector is not corrosion, it is CRC Corrosion Inhibitor.

After a light spray of mineral spirits to remove the dirt that had accumulated the past 3 1/2 years (and letting it dry, I sprayed the braid with another 3 light coats of CRC Corrosion Inhibitor. The connector was attached to the motor (again using a little Permatex silicone grease.

Note that the orange plastic cover does not fit tight around the metal connector. This allows dirt and water to enter the connector - which is probably the root of the corrosion problem.

Keith

 

[RobertB]

I guess I thought that corrosion on that braid worked it's way up to the connector.

This is DC voltage, it’s not 3 phase power. The braided wire you see is shielding. When that corrodes, you start to have issues with AM radio and possibly other symptoms.

Not DC, It is three phase AC. The corroded shielding may contribute to AM static but noise is caused by three phase leakage which will eventually trip inverter ground fault or phase imbalance protection and stop car if leakage is severe enough.

 

[iowagold]

This service campaign now shows up on my dealerships website as a service you can select to schedule an appointment for.

nice. I tried to type in the number for the service campaign at the dealer website and nothing yet.


so I happened to be under the rav4 so I took some pics of where my cable is at right now. last fall I sprayed it with some electronics cleaner and then some marine CRC. doesn't look awful but I'm not a corrosion expert. I reapplied while I was there.

Nasty looking green spots….
Yea shutting the barn door after the fox got in with the chickens comes to mind…
Neutral treatment needed to slow down the attack on the copper…
Then a creeping treatment that will stay in there to protect

Once the green oxide shows up all you can do is slow it down…

And you are dealing with power differential in shield grounds so plating out or electro chemical activity is making things accelerate at a fast pace

 

[CoffeeBear]

So every time I've seen corroded cables it's looked like rusted steel. Why am I seeing what looks like copper corrosion there?

 

[iowagold]

3 1/2 years ago I published a post on the now famous "CableGate: issue: CableGate Post # 507 In that post I stated that I used CRC Heavy Duty Corrosion Inhibitor and Permatex Dielectric Grease. This is what the connector looks like today:
View attachment 221626

Note the 2 holes in the bottom of the orange connector cover. The next picture is the connector with the orange cover removed:
View attachment 221627

Other than the dirt, the metal braid around the 3 wires looks just like it did 3 1/2 years ago.

View attachment 221628

Please Note, the discoloration of the braid and the metal clamp around the connector is not corrosion, it is CRC Corrosion Inhibitor.

View attachment 221629

After a light spray of mineral spirits to remove the dirt that had accumulated the past 3 1/2 years (and letting it dry, I sprayed the braid with another 3 light coats of CRC Corrosion Inhibitor. The connector was attached to the motor (again using a little Permatex silicone grease.

View attachment 221630

Note that the orange plastic cover does not fit tight around the metal connector. This allows dirt and water to enter the connector - which is probably the root of the corrosion problem.

Keith

Looks good and is holding up ok
As an rf guy I am not happy with the gaps in the shield braiding…
Poor design in the cable for this use..

Yea water and minerals are the makings for a bad day when you add in some electricity in the mix.

They need to take lessons from the old classic pots telephone BIG cabling
They use nitrogen to push water out of the jacket and use corrosion control the techs slang as icky pick.
Nasty ultra sticky stuff that it takes gasoline soaking to melt it..
It gets everywhere when dealing with phone cableing trunks like a 1700 or 3600 pair trunk for splicing…
The new fiber stopped having to deal with that.

Maybe in the future they might go a fiber optic for the lan in automotive
Then only have to deal with fat power wires for connections
And seal up the control modules 100% if used outside the passenger cabin.

Potted black box stuff…

God only knows what that will do to the price to an over priced modern automobile ….

Everything breaks or goes bad over time
It is all about lasting as long as the rest of the automobile…
And doing it on the cheap…

 

[Keith_A]

Looks good and is holding up ok
As an rf guy I am not happy with the gaps in the shield braiding…
Poor design in the cable for this use..

Yea water and minerals are the makings for a bad day when you add in some electricity in the mix.

They need to take lessons from the old classic pots telephone BIG cabling
They use nitrogen to push water out of the jacket and use corrosion control the techs slang as icky pick.
Nasty ultra sticky stuff that it takes gasoline soaking to melt it..
It gets everywhere when dealing with phone cableing trunks like a 1700 or 3600 pair trunk for splicing…
The new fiber stopped having to deal with that.

Maybe in the future they might go a fiber optic for the lan in automotive
Then only have to deal with fat power wires for connections
And seal up the control modules 100% if used outside the passenger cabin.

Potted black box stuff…

God only knows what that will do to the price to an over priced modern automobile ….

Everything breaks or goes bad over time
It is all about lasting as long as the rest of the automobile…
And doing it on the cheap…

I'm also a retired electronics engineer.
Yep, that braid clearly doesn't cover the 3 cables that it is supposed to be shielding. I guess the Toyota engineers thought it was "adequate".
At the rate of deterioration that cable will probably last longer than me.....

Keith

 

[CoffeeBear]

At some point is there an expectation that there will be some work instructions (maybe not the right term) for the repair? As has been mentioned, if there is corrosion that should get fixed before wrapping everything up right????

 

[DME21]

Just called my dealer (where I bought it, not the place on the other thread!). They will inspect the cable while I wait on Friday. They will then either schedule to do the wrap or order a new cable based on their findings. So, at least at this one, they know to check before covering!

 

[CoffeeBear]

Just called my dealer (where I bought it, not the place on the other thread!). They will inspect the cable while I wait on Friday. They will then either schedule to do the wrap or order a new cable based on their findings. So, at least at this one, they know to check before covering!

I have to think that anyone who has driven the RAV4 in actual winter conditions for a season or more would have the start of some corrosion but maybe not.

 

[iowagold]

At some point is there an expectation that there will be some work instructions (maybe not the right term) for the repair? As has been mentioned, if there is corrosion that should get fixed before wrapping everything up right????

Yup
Got to stop the reaction before sealing in the damage or it will trap the reaction and make it worse

 

[msauerlpc]

Thank you for pointing out the service campaign. I just made an appointment at my dealer for Friday morning. This is a good example of how this forum serves its members.

 

[Variman]

I just received this notice on the Toyota App today on my 2019 J Vin.

 

[Automatic]

So every time I've seen corroded cables it's looked like rusted steel. Why am I seeing what looks like copper corrosion there?

Must be some copper in there.

 

[2019 Perogi 4]

Is anyone seeing unlimited mileage coverage for this cable issue or just 100k miles 8 yrs. That's what my dealer told me

 

[FKHeath]

The new service campaign detail I post on the other thread make it clear that it is unlimited miles if you get the job done:
https://www.rav4world.com/threads/service-campaign-alert.342531/unread