Harness Rebuild

[Chalky]

Looking to start the rebuild/repairs on the wiring harnesses' for my 84 t-top project. I have the original harness and a couple of spares.

I am hoping to repair the harness to like new condition and am looking for advice on the best materials to use and some good sources for said materials.

[MikeFleming]

The *best* materials would be a later SVO harness, with pin ends and things already installed. Then just swap wires. However, you're probably not likely to find a good condition 84 harness to pilfer from although an 86 harness will have most of the same colored and length wires you will need.

Practice your soldering skills and get a heat shrink heat gun. Make small diameter butt-splices (that is NOT a Kamra Sutra chapter, btw) and slide heat shrink tubing over them, then shrink it in place.

Fan electrical wires, headlight power wires in the electrical harness. TFI, TPS, CTS harness stubs in the EEC harness are the most damaged afaik.

Get some high-temp (200-250F) rated vinyl wrap. Most of the stock harnesses use a non-adhesive black wrap while some sections use sticky electrical tape. and get an assortment of that flex plastic stuff to cover the harnesses.

It's been a while since I last repaired an SVO harness but I have gobs and gobs of pics of the process. Would probably make an interesting tech thread.

If you have the shop room, make up a plywood board with assorted 2x4 wooden stand-offs to mount the harness on that keeps the original shape of the assembly then you can easily change one wire/cable and re-wrap it to keep the same shape. Re-usable tie-wraps are a help here or just waste electrical tape (that leaves no residue).

[Chalky]

Mike, i have several 84 plus a low mile 86 harness to source wires, fuseable links and connectors from. I'd love to see a tech article about the procedure although I've done plenty of wire repair/splicing in my career. I've already got a bunch of the corrugated harness covers.

I like the idea of the plywood boards. I could mount the harness on that and then hang it from the garage wall when not working on it.

[Patrick]

It's called a "Breadboard". Get a piece of pegboard with the holes in it, and the hanger thingies that fit in to the holes. Do the layout and duplicate with new parts. Just about everything is still available new except for the detonation sensor harness connector.

[MikeFleming]

I'll work on posting pics and stuff on my most recent SVO harness repairments. Will give me something to do over the weekend.

[Chalky]

Pat, who are you're recommended sources for electrical stuff???

[Patrick]

Motorcraft used to have a downloadable terminal connector catalog in PDF format at motorcraft.com. I don't know if it's available online anymore. I'd order the Motorcraft items from my wholesaler. Some obsolete items no longer available there could be found in the Au-Ve-Co catalog (again, either through a wholesaler due to minimum order requirement restrictions through the manufacturer. Too bad the Ford attorneys shut down Fordfuelinjection.com. That guy had most of what you might need. He also made complete injection looms. There may be a Motorola techie up near you who has a few sources as well.

UPDATE:
The old Fordfuelinjection.com site is now http://oldfuelinjection.com/
and http://www.rjminjectiontech.com/ .

[MikeFleming]

You could also use one of our own references on the Useful Links page:

http://www.svocop.com/Articles/Ford%20Wiring_Pigtails_Catalog.pdf

[Patrick]

A few AuVeCo catalog pages:
Ford connectors start on page 189.
http://eporia6.eporia.com/resources/company_97/2009 Section 12.pdf


Ford clips and fastners:
http://eporia6.eporia.com/resources/company_97/2009 Section 20A.pdf

Your nearest AuVeCo dealers:

Perfect Fit
2345 N. Ross Ave.
Portland OR 97227
503/234.9325 , 800/333.5858

18249 Olympic Ave. S.
Tukwila WA 98188
206/682.7161 , 800/652.5202

[Meotchh]

Just a few sources to search through. The heatshrink source is very helpful & the prices are pretty good.

http://www.powerstream.com/Wire_Size.htm (http://www.powerstream.com/Wire_Size.htm)

http://www.casperselectronics.com/store2/

http://www.heatshrink.com/products.htm

http://www.fordparts.com/Products/WireSets-WiringPigtailKits.aspx

http://www.ronfrancis.com/departments.asp?dept=7

http://terminalsupplyco.com/Default.aspx

[Chalky]

Thanks for all the tips, tricks and links. I'm going to go through all my harnesses, find the best one, ID all the connectors against my large wiring diagrams and EVTM's, mount on a board and repair and replace as required. I'm going to document the original so I can make it look like new for the t-top.

[MikeFleming]

I have a number of pictures of a new 84 EEC harness if needed.

BTW - Mix up a large bucket of Simple Green and water, in a 1:5 to 1:10 ratio and warm it up to about 100-120F. Drop the harnesses into the solution and stir mildly. This will soften and remove most of the accumulated oils, crud, grease and other miscellaneous 25 years of car crud that collects on wiring. Then rinse with clean water and let them air dry befoe mounting the harness(es) on the rack for disassembly.

[Chalky]

Mike, post away mate, i'd love to see the pics.

[8T6 SVO]

One things to note from when I restored a harness from my 86 in the past was the tape.

It appeared that the cloth type electrical tape was "white" in color. Through further research and the help of Matt Walker, I found that the tape had faded to this white color over the years. I remember the 1984 electrical tape being a little different from the 1986 tape.

The thing that "pops" with the electrical re-wire is the correct wire harness covers (corregated) and electrical type used. The wiring itself, is a whole different story.

[Bob Holmes]

Great thread.

Chalky, are you trying for a restoration type r&r or an upgrade. I'd certainly change to some upgraded wiring and relays for a few things if you aren't.

I had to separate the alternator connector with pliers, again, because of the melted materials on the charging pin. That gets replace, this time. The fan and probably the headlights are going on a couple of relays. As will the water/methanol injection pump...

[Chalky]

Bob, it's for the t-top so it's going to be a close to original as possible. If I can somehow hide relays or better wiring I will but I'm going for more of a concours look and feel.

As for cleaning it, I was just going to chuck it in the dishwasher one day while Sada is a work:):):)

[Robertosvo]

Caroth had a few good ideas when he built his harness ...using some relays in areas to help with weak points in the original harness. If total originality is not required think of connectors to facilitate easy engine/head removal.