Melted Diff Lock Harness 1999 LC (1 Viewer)

[1999WhitePearl]

So yesterday I left work on my lunch break and noticed that the ABS and Rear Diff Lock lights came on while driving and I obviously had not turned the switch to engage the locker. I couldn't find anything in the forums, so I got out the FSM and it called for a short in the Diff Lock harness. (Page DI225). Has anyone with a 98 or 99 had this issue? The wire loom has melted off as well as the insulation off the wires. Kind of scared to drive it as is. See pics

 

[1999WhitePearl]

Do any of you think this is something that I could tackle myself to fix or should I take it to Mr. Toyota? I'm pretty good with a soldering Gun but this seems like something I should let Toyota handle.

 

[yotasavg]

If you can solder you can fix this. I could be wrong, but I also believe you can buy a replacement harness. Maybe one of the parts gurus can chime in... for example, CruiserYard has a whole diff for sale, and includes the locker harness: 100 Series, Rear E-locker Diff / Third Member with wiring harness

I have not personally experienced this.

 

[arcteryx]

You can see if the harness is new but splicing would work so long as you match everything.

 

[1999WhitePearl]

You can see if the harness is new but splicing would work so long as you match everything.

Replied to your email. Anyways I'm sure I could splice it all up, just worried about matching because of the lack of insulation on almost the whole harness... you can't tell what wire is what. Lol. Be easy to buy one new if it didn't cost an arm and a leg.

 

[arcteryx]

Replied to your email. Anyways I'm sure I could splice it all up, just worried about matching because of the lack of insulation on almost the whole harness... you can't tell what wire is what. Lol. Be easy to buy one new if it didn't cost an arm and a leg.

I believe it is 82164-60171. I tried to look at mine but it was partly rubbed off , but with some sleuthing I found it. It's a long piece btw, mine is about 5 feet I would guess. Still available AFAIK. @beno would know and could get it for you.

 

[1999WhitePearl]

I believe it is 82164-60171. I tried to look at mine but it was partly rubbed off , but with some sleuthing I found it. It's a long piece btw, mine is about 5 feet I would guess. Still available AFAIK. @beno would know and could get it for you.

Sweet. That helps a ton. Thanks

 

[1999WhitePearl]

Ok just a little update on this.

Taking this harness off the truck is a B*TCH. You could do it by yourself, but having an extra set of hands helped a lot.

The first thing you need to do is undo the harness from the rear Diff. There is an "S" shaped clip of sorts that holds the harness in place on the Diff. There are two plugs located on the Diff.

Next is the sucky part. There are multiple retainer clips that hold the harness onto the frame and the second to last crossmember of the truck. There is also a "Y" where the harness branches off above the PS cool spring.

This will lead you around to the driver side of the truck where the harness splits to the front and rear of the truck. To the front of the truck, the harness goes to what I believe is one of the ABS sensors? That would explain why my ABS light is on. There are more rentainer clips located on the DS of the frame and crossmember.

Lastly, there is a rather large plug right behind the rear bumper. Unplug this and you're home free!
Here's some pics of the harness it's self. Was too busy cursing the truck to take pics of the harness on the truck.

Sorry the shop is a mess. Too many projects and not enough time to clean...

 

[yotasavg]

Nice work so far, I take you're taking the repair what you have route?

 

[1999WhitePearl]

Nice work so far, I take you're taking the repair what you have route?

Yeah, it's not as bad as it seems. I have the wire to fix it, just need to get some vacuum line.

 

[karicruiser]

I have this exact same issue. I ordered a new harness, and the dealership told me they would have to take the body off the frame to replace the harness. I took the new harness and told them I'd figure out something else. Is removing the harness a huge pain in the ass without having a lift? I'm thinking about taking the new harness to a trusted local shop to see if they would replace it for me.

 

[AimCOtaco]

My exhaust burned through mine once but the damage was more localized. Be sure the breather hose for the e-locker has not been melted or blocked off in the mele.

Probably not a great situation to handle at the dealer, they don't repair as much as they just replace and as you've found it's not easy to full swap the part. That harness is not a normal wear and tear item so will be more expensive than commonly consumed parts from T as well.

Looks like OP has it covered for a good repair but if you don't want to do it yourself, better auto electric shops should be able to replace individual wires from connector pin to connector pin with the right tools.

 

[Trukdiver]

Thank you very much for this post. I just picked up a 1999 to add to the fleet (also have a 2004) and it has this problem. No dash lights are on. I just saw the wires hanging there completely melted through. I guess this big question is what caused this...

 

[diego355]

Thanks for this post, last saturday I had my abs and rear locker lights flashing randomly like a loose connection kinda thing. Ill inspect and fix the wiring

 

[DVader]

Thank you very much for this post. I just picked up a 1999 to add to the fleet (also have a 2004) and it has this problem. No dash lights are on. I just saw the wires hanging there completely melted through. I guess this big question is what caused this...

Generally a hole in the back of the muffler will cause this. I have the same situation, will likely replace with new OEM harness (cost around $91).

 

[Trukdiver]

Generally a hole in the back of the muffler will cause this. I have the same situation, will likely replace with new OEM harness (cost around $91).

So, did you do it yet? I have the part, but haven't started on it. Weather is nice and the garden has been planted, so I'm thinking it could be time.

 

[DVader]

Ended up not replacing. Wires were not totally toast so I separated and re-coated the individual wires with new rubber, then wrapped the whole harness with heat shield tape. It was relatively easy as I replaced my muffler too so I had large area to work with. While in there, changed my rear shocks too since easy to access.

 

[diego355]

Reviving this thread just in case someone needs more info.
If your 100/LX has a functioning AHC this harness won't work
Mine had AHC and was converted to conventional suspension long time ago so the harness works.
Removing the spare tire gives you tons of extra room
If your AHC doesn't work or your suspension has been converted you can cut the plugs. There are 2 extra plugs per side on top of the coil spring that are almost impossible to release
Mine came out in pieces as you can see

 

[SR5BFG]

Reviving this thread just in case someone needs more info.
If your 100/LX has a functioning AHC this harness won't work
Mine had AHC and was converted to conventional suspension long time ago so the harness works.
Removing the spare tire gives you tons of extra room
If your AHC doesn't work or your suspension has been converted you can cut the plugs. There are 2 extra plugs per side on top of the coil spring that are almost impossible to release
Mine came out in pieces as you can see

View attachment 2891259

View attachment 2891260

View attachment 2891261

Do you have any suggestions for one trying to replace the rear harness? I tried following the harness with my hand, but lost it over the left frame/ cross member junction. Is this where the connectors are located?

thanks,

-SR5BFG

 

[diego355]

Do you have any suggestions for one trying to replace the rear harness? I tried following the harness with my hand, but lost it over the left frame/ cross member junction. Is this where the connectors are located?

thanks,

-SR5BFG

There are 3 plugs on top of each coil spring.
The smallest ones are for ABS sensor wires (grey 2 prong connectors)
The other 2 per side I followed them and it leads to the AHC globes
The 2 bigger plugs sit on the drivers side behind the rear bumper
From the wheel arch you can break the zip ties that fix the plugs to the frame to have a bit more room for unplugging them