Melted Wiring Harness

Darren Technician Wisconsin Posted   Latest  
Resolved
Electrical
2015 Isuzu NPR 6.0L (G L96 297hp)

Underneath this box truck the hole in the muffler melted a wiring harness. 

Here is my question…..

There are several wires with the same color < green with a black tracer> that go in and 

out of this melted section, also some < green with a white tracer> .

I would never assume to know which wire goes where, just because there are the 

same color doesnt mean they are interchangeable.

All the wires are shorted together in the melted section, so an ohmmeter is out of the question.

I do not have a wiring diagram which would really help, and I do believe most of these wires are 

for exterior lighting.

Any help at all would be much appreciated on how to move forward.

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Kevin Technician
Alberta
Kevin
 

Get me a vin + email adress

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Glenn Owner/Technician
Texas
Glenn
 

The insulation is melted but not the wires inside usually. Use a heat gun and gloves to heat the bad segment and pull it apart the insulation without breaking any of the wires. Hopefully you have not jumped the gun and cut the bad section out already. Once you get them separated, install a repair section in one wire at a time. This method takes time but is the best way to handle this in my…

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Helpful
Interesting
Jesse Owner/Technician
Pennsylvania
Jesse
 

Hi Darren ,try the bodybuilder guide, which is used by body upfitters, website that i found pdfmanuals4trucks​.​com also try izuzutruckservice​.​com look for body buildersection, then go thru selection process, bodybuilder giudes can be super for some of these types of situations. also bodybuilder guides are often free and can blow the doors of regular service info. good…

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Louis Owner/Technician
New York
Louis
 

Darren, Glenn's strategy is excellent. However for the actual wiring repair work I would use SXL wire, and this is because they are far superior to any other wire you could obtain from the parts store. I highly doubt that any parts store you deal with carries SXL wire. delcity​.​net can supply you with SXL wire, along with MIL spec. adhesive lined heat shrink tubing. Louie

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Darren Technician
Wisconsin
Darren Update
 

Ok, got some free wiring diagrams suggested by Jesse. Gonna take Glenn’s advice moving forward. Thank you guys, huge help!!!!

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Glenn Owner/Technician
Texas
Glenn
 

Hi Darren, I have been tasked with many burn damaged, pinched and shorted harness jobs over the years. What doesn't kill you only makes you stronger. LOL.

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Mark Engineer
Colorado
Mark
 

Darren I agree, it appears that the wires are all the same. Sometimes (and I emphasize sometimes) the wires actually have a three-digit number on the insulation. Often the numbers are only every foot, so you might have to remove loom and you might see the three-digit number. Possibly this can help bring the harness back into service I think some companies use ink-jet, others use LASER printers…

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Darren Technician
Wisconsin
Darren Resolution
 

Got this one resolved, followed Glenns advice, super clever by the way, worked like a charm!!!

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Glenn Owner/Technician
Texas
Glenn
 

Glad it worked out for you.

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