1986 FJ45 Wiring Harness Search (US)

[ttebroc22]

I’m searching for a replacement wiring harness to install in my 1986 FJ45. The current one is melted and not able to be repaired. This forum was recommended by several vendors who were unable to help.

Any suggestions or input appreciated.

 

[pbgbottle]

if it is truly a 1986 that is a rare rig. They only made a few of them and they came with no box just a cab chassis. Not sure what the wiring harness would be like in 1986 as these are not suppose to exist. But the Toyota parts catalog does show part numbers for a 1986 40 series. Post a pic of your truck. Cheers

 

[WarDamnEagle]

I don't see anything past 09/85 in the data base I am looking at. If it truly is a 1986 then it's rare indeed. Please also post a photo of the VIN plate on the firewall.

I think the only thing you could do at this point is assume the wiring diagram is the same as a 1984 and have someone rebuild the wiring harness. @Coolerman probably could do it but I'm not sure he still rebuilds/refurbishes entire harnesses. Maybe someone knows of another vendor that can do it.

 

[Unimogguy]

I installed a Painless Wiring harness after my harness caught on fire in my ‘73 RHD FJ-45.

 

[charliemeyer007]

Good luck
This might get you a start

Coolerman's Electrical Schematic and FSM File Retrieval

 

[charliemeyer007]

Wiring up an old one from scratch was sort of easy; didn't have seat sensors, air bags, computer controlled vents/fans/vac switching, spark, fuel injection, NASA reporting to the CIA on the smog apparatus and the fuel cap leak....

 

[cruisermatt]

We can rebuild it @ CruiserMatt’s

I am doing one for a semi local customer now
We have all correct color-striped wire, terminals, connectors in stock.

Not cheap or fast but it’s right.

Waiting on a payment to complete this project but when it’s finished I’ll lay it out with a battery, all switches, gauge cluster, all lights, on the floor and make sure all functions work.

 

[ttebroc22]

Well…
Thanks so much for the feedback. This may explain why looking for 1986-ish anything has proven so difficult. I’m attaching some pictures as requested and look forward to any further responses.

 

[OGBeno]

It’s a CKD truck and not a cab/chassis (FJ45-Xxxx3)

-9xxxxx are CKDs.

 

[ttebroc22]

It’s a CKD truck and not a cab/chassis (FJ45-Xxxx3)

-9xxxxx are CKDs.

Thank you.

 

[OGBeno]

Thank you.

I would recommend starting with a good used harness and have one “rebuilt” so to speak. That’s generally what we do here and other shops do as well.

Each truck will be slightly different in terms of wiring so there is no “one-harness-fits-all” solution. And certainly not one off the shelf.

Ideally you start with a good known year range harness that is close and then using the wiring diagram you reconstruct it. It’s very heavy in actual man hours (billable: easily 30-60hrs to make it look and operate like a factory Yazaki harness).

The Painless universal harnesses suck big time. Don’t go in this direction.

If it’s a South American truck, there might not be much left of your original harness that can be salvaged as it’s probably been butchered by creative South American engineering.

 

[ttebroc22]

I was gifted this truck in 2020 and wholeheartedly admit that this is out of my wheelhouse. It was blindly purchased by the buyer and trailered from Florida to South Carolina so I don’t know much about its past. I recall looking up the VIN around the time it was given to me and conceding that it had been shipped to a destination as parts and assembled onsite. I’m going to assume that this affects figuring out when it was made, parts, et cetera?

 

[OGBeno]

I was gifted this truck in 2020 and wholeheartedly admit that this is out of my wheelhouse. It was blindly purchased by the buyer and trailered from Florida to South Carolina so I don’t know much about its past. I recall looking up the VIN around the time it was given to me and conceding that it had been shipped to a destination as parts and assembled onsite. I’m going to assume that this affects figuring out when it was made, parts, et cetera?

That is correct.

The historical documentation for CKD trucks (Complete Knock Down Kits) is sparse beyond the assembled knowledge on Internet forums like MUD.

These trucks were “trucks in a crate”assembled locally in a destination country (most likely Venezuela or Colombia).

You can see on the data plate the “UNID” number: Unit Identification Number which would be the numerical designation for the CKD— different than the frame number.

 

[ttebroc22]

That is correct.

The historical documentation for CKD trucks (Complete Knock Down Kits) is sparse beyond the assembled knowledge on Internet forums like MUD.

These trucks were “trucks in a crate”assembled locally in a destination country (most likely Venezuela or Colombia).

You can see on the data plate the “UNID” number: Unit Identification Number which would be the numerical designation for the CKD— different than the frame number.

Thank you so much! I was told that the truck was imported from Venezuela in 2016 or 2017. I have the old wiring harness here. It’s sort of a melted plastic rope. It’s still together as it was disassembled and we marked the connections as we separated them. I will get some photos and upload them. And, yes, I can see why there would be billable hours involved in rebuilding one.

 

[charliemeyer007]

There isn't that many circuits. Not like there are 107 computer modules to control everything. Get one of those wire label tags printers and maybe 4 colors of wires and a bunch of connectors - put a tag on the wire every few feet (turn signal left front or turn signal left rear). I would run a black ground wire to every light fixture. You don't plugs you can just put a bunch on connectors in the same place/area. Run all your wires, then put it in the plastic loom protector. Do a wiring diagram as you build it. Doesn't need to be on one page - a circuit/fuse per page would work for me. You can tell I'm not a purest - I just like stuff to work correctly and safely is a real plus.

 

[ttebroc22]

There isn't that many circuits. Not like there are 107 computer modules to control everything. Get one of those wire label tags printers and maybe 4 colors of wires and a bunch of connectors - put a tag on the wire every few feet (turn signal left front or turn signal left rear). I would run a black ground wire to every light fixture. You don't plugs you can just put a bunch on connectors in the same place/area. Run all your wires, then put it in the plastic loom protector. Do a wiring diagram as you build it. Doesn't need to be on one page - a circuit/fuse per page would work for me. You can tell I'm not a purest - I just like stuff to work correctly and safely is a real plus.

Yes, this is definitely true regarding components. I’m inspired to map it out and see what I’m dealing with. Thank you for the input. I’ve got a sixteen year old son dying to drive this truck. Maybe we both need to learn a new skill?

 

[Unimogguy]

@OGBeno

Thanks for taking the time to educate us!

@ttebroc22
Head over to @Coolerman ’s website and he should have all the wiring and potentially all the connectors you’ll need.

Cruiser Wiring

I would build a board like in the pic I borrowed and set up your wiring jig like this:

 

[archie73]

@
[/QUOTE]

[QUOTE="Unimogguy, post: 15852077, member: 163596"]

I would build a board like in the pic I borrowed and set it up your wiring jig like this:

[ATTACH=full]3852313[/ATTACH]
[/QUOTE]
This is how I did my LS harness. It isn’t rocket science, just tedious. Take your time and solder all the joints. No butt connectors!!! I recently bought the printable shrink wrap- where was this when I did my LS?!?!?!

 

[ttebroc22]

Great! I love these suggestions! Y’all are the best.

 

[V8FJ4078]

If you have time, I would get the correct color wires and build it yourself, not terribly hard, but it does take the time others list above. A good wiring diagram helps especially if it is melted.