complete wiring harness replacement

[Dan Crowley]

Hi Danny,  Good luck with the AAW kit.  I still think it would be a good idea for you to order a Ron Francis catalog which is free, it has a lot of information on wiring with tips and do's and don't s.  I found it very helpful to me and I need all the help I can get.

[Danny Campbell]

Thought I would provide an update. I was able to successfully remove the chassis harness intact. I did separate the the connections than ran under the driver side frame rail to the back of the truck, leaving the complete wiring system in four sections (glow plug harness, charging and starter harness and the main chassis harness). Pictured on the ground is the chassis harness with the two branches that fed through each side of the firewall.
The harness is in relatively good shape, with the exception of hackery at the brake switch, glow plug relay and radio. The charging harness was butchered up as seen in one the photos. Evidently the air conditioner was upgraded to r134 setup and the wiring for the compressor was juvenile. I was surprised by the lack of grounds for this harness, only chassis grounds and none to the frame. It’s no wonder I was having ground troubles.

Now that the harness is out, I will start tackling other issues. I hope to began documenting the installation of the new wiring harness soon to this thread.  It will include a complete harness replacement of the entire truck, 200 amp single wire alternator upgrade and a custom built fuse bock with a relay bank to run newer tech.

[Gary Lewis]

Well done!  I'm following along as there's lots to learn.