Thu Mar 15, 2012 12:08 am
It's not corrosion that causes the most common failure - it's a phenomenon known as "work hardening" where the copper of the wires becomes brittle as a result of vibration from the diff causing changes to its crystalline structure .
This often causes the wire to break internally in the vicinity of the diff., with nothing visible externally. Gently pulling the wire will identify the site of the break by seeing where the plastic sheath stretches.
Because the "work hardening" is irreversible, except by heating the wire to red heat, the last 300mm of wire to the diff, including the plug buckets, should be replaced, rather than a repair attempted.