The 3cm Fracture Zone: A Production Line Autopsy of OBD2 Cable Failures

Technical analysis highlighting the critical 3cm failure zone in an OBD2 diagnostic cable assembly, with lab tools and engineering drawings.

If you’ve spent time diagnosing vehicle electronics, you’ve witnessed this ghost in the machine. A scan tool display flickers. CAN bus communication drops. Jiggle the cable where it meets the OBD2 connector, and functionality returns—temporarily. In our Failure Analysis Lab, this scene has a physical signature: a fracture line, consistently appearing three finger-widths from the connector […]