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The_Hammer

Straightening out wiring harness.

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There's got to be some story behind it?  It wasn't just laying under your truck when you went out to start it was it?

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That's the complete harness from the PCM, to the engine, and transmission. I'm getting rid of random plugs that aren't used for this truck, replacing all the brittle tape and loom, as well as cleaning up old splices.

7 minutes ago, Hawkez said:

There's got to be some story behind it?  It wasn't just laying under your truck when you went out to start it was it?

That just literally made me lol!

All the loom and tape were falling to pieces, which ended up with random wires floating around just waiting to short out. I also wanted to get rid of all the unused connectors and their wiring. All of the plastic wiring holders are broken as well, which I'm going to replace. Basically just preventive maintenance.

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1 hour ago, Hawkez said:

That looks a lot better than the first picture.

Thanks.

You know how sometimes doing repairs and fixing up your truck is fun and enjoyable? Well this ain't one of those times lol.

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1 hour ago, Mopar1973Man said:

What was so bad about it? :think:

Taking off all the old, cracked up and baked on electrical tape was tedious. Wrapping up a section of harness just to realize you left out one wire sucks too smiley_abused.gif.0062604076b8f66e4cce30. It's not horrible by any means, but I can't say I'm having a blast doing it.

1 hour ago, Royal Squire said:

Hammer-Did you get some of that hi-tech electrical tape for this job?

No. Apparently USPS has found me unworthy of receiving it, judging from the fact that it's been sitting in GA for 4 business days.

USPS.jpg.99188215dc07232638bfdc9bd1a1cda

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Don't feel bad... USPS suppose to have a key lock assembly coming from RockAuto but delivery date is set for the 12th and it in Ohio... Hmmm Today is the 13th and its still not here...

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Sounds like they're having one big SNAFU then.

Harness is back in the truck. I've been shortening up wires that were always a mile too long, like the grid heater wires, grid heater relay wires, and oil pressure sender wires. Also rerouted the tps wires back through the harness up by the ABS unit. I deleted the tps in favor of a potentiometer so I didn't need the wires down by the pump anymore. Also deleted the fuel heater relay harness, along with a random relay harness that isn't used on this truck.

All of the harness loops that were mounted at various points throughout the engine bay were broke, so I used zip ties to secures everything. 

 

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I must have done something right, the truck actually starts and all my gauges work smiley_abused.gif.c30215b2851d377fe6af37. I also noticed that the "wait to start" light works for the first time since owning the truck. 

I do have some questions about the fusible links, which the truck currently has none of.

Is there supposed to be one in-line of the power wire going to the shutdown solenoid relay?

What about for the starter relay?

Should fusible links be two gauges smaller than the wire it's protecting?

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The only fusible links I know on a 12V is the grid heaters and the one for the fuel solenoid that is it.  Beyond that there should be fuses in the PDC or cab for protection of circuits.

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3 minutes ago, Mopar1973Man said:

The only fusible links I know on a 12V is the grid heaters and the one for the fuel solenoid that is it.  Beyond that there should be fuses in the PDC or cab for protection of circuits.

Ok, thanks. I forgot about ones in the grid heater wires, which are still intact.

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Well, my Tesa wiring harness tape came today. Good news is that this works really well, bad news is that I'm going to end up redoing most of the harness with it lol.

rps20160114_161715.jpg.d9192750d5622be66

rps20160114_161746.jpg.47d52608b378056ec

rps20160114_161652.jpg.d3b5e485879c55682

 

A few things need to be said about this stuff.

It is NOT an electrical tape, it's a replacement for plastic loom. It's meant to be wrapped directly around the wires and not over loom, except for areas of severe abrasion.

It doesn't have a lot of adhesion to it, since it is meant to be easily removed if need be. Because of this, you'll want to make a few wraps in one spot when starting and lock the end when your finished. You can lock the end of the wrap with a small zip tie or two.

A couple of rolls ($32) would be enough to wrap the entire under hood and transmission harness. 

So far I really like the stuff and will be using it in place of plastic loom.

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2 hours ago, Me78569 said:

You are putting bad ideas into my head.

Honestly, it not that difficult to do. It only takes about 30 minutes to get the harness out.

Here are some tips from my experience;

Think ahead before you start removing the harness. Are there random unused connectors floating around that you'd like to remove? Are some wires a mile too long, while others are too short? Do you want to change the way some of the wires are ran? Plan all of this out before you start, it will make things go easier. 

I used uninsulated butt connectors and heat shrink tubing when shortening wires, I highly recommend them. Also, make sure you stagger the connectors to keep the profile as minimal as possible. 

One thing you do NOT want to do is completely unwrap the entire harness at one time, it will make keeping the various plugs in the right location more difficult.

Since the ends of the harness tape need to be secured, try to make as long of wraps as you can. Wrap connector wires first, tying the wraps in to the main harness. This will allow you to wrap over the ends when wrapping the main harness, eliminating the need to secure the ends of the connector wire wrap. 

Edited by The_Hammer
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12 hours ago, The_Hammer said:

I do have some questions about the fusible links, which the truck currently has none of.

Is there supposed to be one in-line of the power wire going to the shutdown solenoid relay?

What about for the starter relay?

Should fusible links be two gauges smaller than the wire it's protecting?

The Fuel Heater and FSS both get 16ga fusible links.  I don't know what the grids get.  The starter I'm not sure about, if it does, it's under the insulation.

 

I'm with Nick on this one.

Edited by Cowboy
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27 minutes ago, Cowboy said:

The Fuel Heater and FSS both get 16ga fusible links.  I don't know what the grids get.  The starter I'm not sure about, if it does, it's under the insulation.

 

I'm with Nick on this one.

The fuel heater and it's wiring are gone. I've got a 16ga fusible link for the FSS, I wanted to make sure it was correct before installing it. The starter relay power wire has been replaced somewhere along the line so there isn't a link installed. The grid heater relays do in fact have links. I'm wanting to make sure everything is set up right. I've had wiring burst in to flames on a previous vehicle before, due to shoddy wiring by the previous owner. 

Edited by The_Hammer

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