Last weekend while on the trail I smelled burning. Popped the hood and sure enough had a fire. Fortunate enough to get it out in time and continue on for the evening. Today I chased the harness back to attempt to make repairs. What I found was less than ideal to say the least. The wire that I believe arced is the center wire of the cruise control actuator ( cannot see color of sheathing from burn) this wire is completely fried all the way back past the fire wall. It claimed other victims along the way as well. This section of harness appears to be to my front locker, wiper motor as well as cruise control. My original plan was the re-protect all damaged wires and wrap up the harness but now seeing that I need to somehow get past the firewall has thrown a wrench in things. Anyone have any viable options to make repairs other than pulling my entire 31 year old Arizona weathered dash to access cab side connector? Any tips to removing the grommet on the firewall side? At a total loss here and to be honest all I am concerned about is making the harness safe again and not prioritizing resorting cruise control… never had to deal with this sort of thing before. Appreciate any help. Thanks
That grommet is installed from the inside a couple of plastic trim tools (preferred) or small screw drivers should be able to force out of the opening.
That portion of the harness extends from the interior, and is part of the dash harness (Front Wiring Harness), so would not be an easy replacement, you will probably need to repair in place, but you will need to be proficient with soldering, heat shrink, and crimping pins. You can look for that grey connector in the wire harness repair manual (in the resources section) (you can confirm the part number on the housing)
I believe from the pictures, the gray connector that appear most affected are:
7P Waterproof Type:
Female Housing: 90980–10931
Male Housing: 90980–10930
Repair wires:
Female Repair wire with Terminal: 82998-12440
Male Repair wire with Terminal: 160mm length: Blue (~18 Gauge) 82998–12430;
500 mm Length: Blue (~18 Gauge) 82998-12590; Yellow (~14 Gauge Wire) 82998-12800
Bare Pin Contacts:
Mfr: Yazaki
Series: 090II Sealed Series, RK/090II Hybrid
Female Pins:
0.3-0.5 mm2 (22-20 AWG): Tin Plated 7116-4025 (Gold Plated 7114-4028-08)
0.85-1.25 mm2 (18-16 AWG): Tin Plated 7116-4026 (Gold Plated 7114-4029-08)
2.0 mm2 (14 AWG): Tin Plated 7116-4027
Male Pins:
0.3-0.5 mm2 (22-20 AWG): Tin Plated 7114-4025 (Gold Plated 7114-4028-08)
0.85-1.25 mm2 (18-16 AWG): Tin Plated 7114-4026 (Gold Plated 7114-4029-08)
2.0 mm2 (14 AWG): Tin Plated 7114-4027
There are several vendors on this site that may be more affordable than going directly to Toyota for the repair wires; the pins are generally only available from non-Toyota dealer sources.
It may be “easier” to pull the fender to access if all the wires on the outside are serviceable and can be repaired.
Here is a picture of that portion of the wiring harness from Cruiseryard of a used front harness they have listed:
It also looks like more wires than what goes to that gray connector were also affected, so those will need to be researched.
