I thought I had a blown speaker, but.....

ViperCollector

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It looks like it is something more involved.

Background: When I purchased my '01 GTS, I 'thought' the left front speaker was blown. Didn't think too much of it, as I knew my first 'mod' would be to upgrade them. Today my new set of Polk DB651 arrived, so I began the project immediately. I will note a couple things for anyone else doing the install.

First, my wiring is different that what I saw others post here. My factory wiring has a dark green going to positive and light green leading to negative. Yes, I had to drill these speakers to allow for the 3 hole factory covers. You cannot use the new Polk covers, as they do not recess and the door will not close. You also cannot use any of Polk's supplied gaskets/adapters as they add too much thickness to the speaker, again causing the door to not close. The only way these will install is to drill out three new holes. I got lucky on my right door, as I was even able to get the small 'Polk' name at the 12 o'clock position. I wasn't even trying and can assure you the driver's door will not match.

The factory cover is a TIGHT fit over the speakers, much tighter than factory. This is compounded by the fact that the cover WILL rest on top of the center (tweeter?). What this does is try to force the cover to pop off while you're trying hard to line up the three screws. An extra set of hands did help a little, but it is more about trial and error.

Here is where I have an issue I need 'help' with. I first removed the bad speaker (so I thought) on the driver's side and hooked up the new speaker in my hand. Turned on the radio and nothing!!! Hmm, disconnect the good one on the right (this was before installing the new one over there) and hook it up and it works fine. Then I hook up the what-I-thought-was-blown speaker to the passenger side, and it works too..... So, there is no signal reaching the speaker at all on the driver's side. I went ahead and completed the install on the passender side, and WOW, the difference in sound is well worth it, even in one speaker!

I started looking closer as to what may be the issue on the other side, checked the hatch and both speakers working fine back there (so it isn't "left side" issues maybe from the unit). I then notice something I hadn't seen before (and neither did the Viper Tech that inspected my car). The pass-through rubber-thingy on the driver's door has electrical tape on it. I start removing a couple layers, and hear a 'click click' sound whenever I move it with my hand. Something in there sounds like it is shorting, although I'm not having any battery issues at the moment and the door is operating normally. Moving it around didn't get the speaker to kick in either, but there appears to be an issue between the amp and the speaker and now this 'click click' sounds that concerns me. Doesn't look like an easy area to get to and work on, so at this point I am still with only one speaker (albeit a nicer one) and looking for opinions/thoughts/etc on what should be my next step.

Thanks in advance for your thoughts!
Scott
 

Copernicus

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The wiring harness in the door probably pulled the wire. The 'click click' noise is probably the wire mometarily making a connection. I would pull all the electrical tape off and go through the connections. You will probably see a few other wires that are starting to pull apart as well.
 

GTSnake

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It's the old door harness problem. Do a search and you will find a ton of posts about repairing broken wires in the door harness.
 
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ViperCollector

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Will do the search right now. I figured the 'click click' was wires making contact, but since it does this with power off, I know it isn't the speaker wires. Probably power going to the door lock or something of the sort.
 
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ViperCollector

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An update after this morning's project! Unhooked the tubing and found four wires that had previously been repaired. They over-repaired them, and they all failed/are failing. Three were completely broken off, and the other will one day soon.

I repaired the three broken ones, but skipped the fourth as it hadn't broken yet, and it doesn't appear that I'll have much (any) slack left to work with if I clip off their repair area. The 'click click' is still there and couldn't tell 100% if it was that last wire or another one, but the rest appeared fine. The good news is the speaker now works (new one installed)!!! I am curious about the other two wires that were broken and I repairs (pink and beige). I wonder what they were for? Does anyone know of a wiring diagram for that harness? I hadn't noticed anything not operating, and am not noticing anything new yet.

On a side note - anyone have a link to a good soldering tutorial (for dummies)? My skills are awful and I gave up doing the speakers and just hand-tightened the wire onto the leads. I know I'll eventually have to open them back up and connect them more permanently.
 

InjectTheVenom

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The best soldering tip that I got was to hold the soldering gun under the wires that you just twisted together to make the connection hot enough, when it does the tin will start to melt and sink it's way into the wires to make the connection rock-solid. It takes some practice, patience and good equipment but it will get you a good result.
Oh, I hope you will be using a small piece of shrinkdown hose to decently cover your work ;)?
 
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ViperCollector

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Yep, used shrinkdown hose over the new splices, as well as a little tape just to make sure. Figured out what one of the 'other' wires was - was the 'door ajar' notification. Never saw it light up before, but sure noticed it now (always worked fine on the passenger side).
 

GTSnake

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Did you give each wire a tug to make sure it's not broken inside the insulation? I've found a few that were broken inside but intact from the outside.

When I solder the wires I always add a little extra wire so there's no more tension.
 
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ViperCollector

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Nah, I didn't tug on any others since I'm not having any other issues at the moment (except for the clicking sound). And I really didn't feel like doing any more than I did. The ones I had to deal with were so close to the chassis that one slip with the wire trimmers and I'd end up replacing the whole harness. I did give some extra slack to my spliced wires, and coiled them around the other bunch to help with the bending. All I had around was some 16gauge wire, so my splices are a bit thicker than the other ones.

The previous owner butt-spliced them with a super thick shrink tubing over them (about 1mm thick all the way around). Those got brittle and cracked, but did last a few years.

Guess I'll keep my eyes open for a harness from a wreck if they ever come up. The OEM price is exorbitant!
 

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