Common Failure Points in Custom OBD-II Cable Assemblies: Bridging the Gap from “Passing Tests” to “Field Failure”

Forensic engineering illustration: OBD-II cable connector bridging a gap between a clean laboratory test bench and a harsh, vibrating engine bay, symbolizing the transition from passing tests to field failure.

Your custom OBD-II diagnostic cable assembly passed all tests in the lab. However, once in the aftermarket or integrated into the final product, field failure reports begin to surface: intermittent communication loss, diagnostic tool connection drops, sporadic U-code errors. The problem rarely lies in simple continuity; it hides in the grey areas of material fatigue, contact […]