Wiring Harness Repair

[annihil8ted]

Hello, the last owner of my LJ put in an oversized battery and didn't properly strap it down which ended up letting the battery abrade through a couple of wiring harnesses. For the damages shown below, what would be the best way to repair? I'm chasing some electric, airbag, and O2 codes and I'm wondering if my damaged harnesses are causing the issue. I know in the past, I've gotten recommendations for splicing and crimping but wanted to ask again with some photos as it seems there wouldn't be enough or would be very tight on space if I went the crimp route

 

[macleanflood]

Uninsulated butt splices on one side for sure. I'd be depining the PCM connector and crimping fresh wire in.

Might want to hit up a junkyard. If you can get the PCM connectors and 1 to 2 feet of wire then you've got correct colors and all you'd need to do is depin the abraided section, click in your replacement, slip on some heat shrink, crimp an uninsulated butt splice in and shrink the heat shrink.

-Mac

 

[annihil8ted]

Ah so crimping is still the way to go and then instead of joining two old ends, replace the shorter side entirely new?

Are there any concerns with corrosion that runs down existing exposed wire sheathing? The exposed strands seems discolored leading me to think it may be due to oxidation and corrosion?

Uninsulated butt splices on one side for sure. I'd be depining the PCM connector and crimping fresh wire in.

Might want to hit up a junkyard. If you can get the PCM connectors and 1 to 2 feet of wire then you've got correct colors and all you'd need to do is depin the abraided section, click in your replacement, slip on some heat shrink, crimp an uninsulated butt splice in and shrink the heat shrink.

-Mac

 

[macleanflood]

Yeah you're going to have to chase wire down that harness until you find clean copper.

-Mac

 

[annihil8ted]

Darn, I was hoping to avoid that but thank you for confirming! Need to do some cost to effort analysis. I don't mind rebuilding the cables but since it's my daily driver, I'd like there to not be that much downtime. May opt to look for a used one

 

[OldBuzzard]

First you need to know how bad it is. I would de-sheath the cable from the connectors down a few inches. See how many wires are damaged, and if any are actually broken or just un-insulated.

If no wires are broken, you can just separate them so they can't short together, and then see if your codes can be cleared. Don't drive it that way though.

 

[LJGreg]

Also consider taking the time to pull the entire harness and do the repair on the bench. It is going to be a pain in the ass trying to work on it still attached. If the loom is in rough shape it would be a good time to redo it as well.