Infamous wiring harness issue (1 Viewer)

[somewelderguy]

1995 fzj80, we just bought it the week of Christmas, everything has been fine up until last night out on some trails and it just died. It would crank all day but would fire off. We left it over night came back first thing this morning and tried to crank it that's when I noticed smoke coming from the wiring harness of the fire wall. Low and behold it had rubbed/burnt right next to egr, I found just on melted wire and a spot where 4 or 3 wires melted to together.
Does anybody know where I can find a new or used wiring harness?
It's still stuck in the woods on my private property once I can figure out a way to recover it and get it back to the house I'm going to pull the harness out, strip it and see if it's fixable. If not then I'll bite the bullet and buy a harness. Just looking for leads on one.
Thanks

 

[jfz80]

New harness is NLA. Not so say some digging might turn one up. ... north of 500. I might be able to locate a used one for you but many have just unwrapped it, repaired the burn wites and wrapped it back up with a heat shield and tied away from the egr. Granted not so easy to do in the woods.

Check iver on old north state cruisers or maybe @Roxx has one for you. Ill dig thru my parts.

 

[somewelderguy]

Yeah, I had a time this morning trying to diagnosis back there, it honestly don't look to bad, judging from what little bit I was able to see.
Hoping once I get it back to the house and tore down I can get a better idea.
That sucks new ones are NLA I was hoping to buy a new one vs used as who knows how brittle or corroded any of the other wires may be.
I guess it's my OCD kicking in and i would just rather swap it vs fixing it lol. I'm not afraid to try to fix it just would like some leads incase it is in bad shape

 

[Marine7]

Just cut out the burnt sections, and CRIMP new wire in. DO NOT solder wire associated with harness, use butt connectors or crush caps. Solder will melt or vibrate loose quickly under the hood. Seems like you could fix it where it’s at. Not ideal, but at least you don’t have bullets plying past while wrenching! lol ....... Good luck!

 

[Roxx]

I may have a 94 i think at one point i had a 95. But i dont know where to start looking for it. Actually @forrest5000 helped me take the wire harness off of the 95. Dont remember where i put it.

 

[Tools R Us]

Most of them are repairable, but the OBD2 harness is available, 82121-60343.

 

[Rifleman]

For those new Mud members who may not know about the damage the EGR pipe can do to your harness, here's a link to a thread with photos showing the aftermath. This is one of those possible problems that's well worth doing something about before it happens. melted engine wire harness