To make a long stoy short, my brake controler fried the under dash wiring harness. The wires for the brake lights, turn and hazards, were melted and fused togther throughout most of the harness all the way to the plull at the firewall. Was told by local dealer a new harness is $1600.00. My question is how hard to run the harness and replace the wires that are melted or shorted out so I can save the $1600 for other uses? Thanks

 

I would get a harness from the wrecker but cut out only the bits you need and solder the new section in, use heat shrink to cover the joints. If you were to use crimps the area at the joints would be too large. I have repaired harnesses that were burnt and usually the wrecker only has harnesses that have ALREADY been burnt. (Fords). In those cases I have made up harnesses and attached plugs where necessary. In most cases if it burns inside the vehicle they write it off as it,s very difficult to get rid of the smell. Good luck, I wouldn't buy the new harness from the dealer..

 

Thanks

Kevin

 

If you're not comfortable doing the wiring you might get the parts you need and take your truck to a local stereo shop. If you shop around you'll find someone who enjoys the challenge and will do a good job. It'll be less headache and less stress for you and probably at a very reasonable price.

For me, I can't fit up under there and reach far enough to get it done correctly!!

 

I had mine burn from a short circuit that was caused by a body shop that did not insure that all of the small harnesses in the cab were back in thier original position. One harness ended up between the parking brake pedal and stop. After several monthes strange electrical things were happening in the cab. Loss of all lights and guages on the dash. Overhead light comes on but the map lights go off when I turn the dash switch on. Then I turn the dash switch off and the overhead light turns out and the map lights illuminate. I took the dash cluster bezel off to see the burnt harness behind the dash cluster. I pulled the dash board out of the truck and removed very carefully the harness. I then spent 11 hours on the floor separating burnt wires that were melted together and I followed them to just past the damage and cut and spliced new wire in. I was fortunate that no connectors were affected or I would have been in real trouble as none of the connectors at the time were available aftermarket and only as part of the whole harness at the dealer ($900.00). I traced the only burnt wire that extended past the damaged area and followed it to the short at the parking brake pedal.
Patience, wire, heat shrink, a good soldering gun, and patience. I suspect I spent about $25.00 in materials. It can be done. Good Luck.

 

Thanks, this is the second time pulling the dash out for this problem. All lights seem to work and not blow any fuses. Then I noticed the fan would come on if I touched the break with the key in my hand. Also, the breaklights would come on if the key was in the on or run position. Still not blowing any more fuses. Pulled dash again and installed a harness I got off of ebay. It is close but not an exact match. Just have to reinstall dash tomorrow. I'm hoping it will work well enough to allow me to drive the rig while I take D2 Cat's advice and find someone to fix my original harness.

Kevin

 

You might check ebay motors as well. I was on there the other day looking for parts and they had a complete engine harness for a 95 dodge cummins. Might be worth a look.

Take care
Steve

 

I had a similar problem on a car & ended up replacing the harness with one from the same year parts car. Harnesses are easy to test when they're laid out on the shop floor. Replacing is easy if you label & take pics. It's amazing how many electrical problems go away when you pull a dash & hook everything according to the wiring diagram.

 

I lucked out. I pulled the plastic race and the melted wires were laying on top. Got it back together this afternoon and she works like new. Thanks for the help and suggestions.

Kevin

 

does anybody know what website i can look around to find this or the product number