Smoked Harness: Lessons Learned

[atomicshawn]

I noticed my taillights were out last week. Found the 15 amp fuse blown. Replaced it. I knew I had to have a short someplace, but it wasn't showing up… No problems until Sunday when I was making a four hour trip home from Island Park. Getting dark. Turn on the lights and no taillights. I had forgotten my tool bag where I keep extra fuses. So I pull over stop at Texaco station where I find a super sweet deal on a box of like 20 fuses for two dollars and some change. I could tell by looking at them how cheap these fuses were made…

But fuses are fuses right? Wrong! I stick in a 15 amp fuse, it doesn't blow, I continue on my way. About five minutes later, flying down the freeway, smokes begins to fill the cabin and I can see smoke even curling out from the hood. By the time I get pulled over I can hardly breathe. Pop the fuse cover off and every thing is melting around the fuse, but the element is intact, glowing red. I frantically fish the pocket knife out of center console and break the fuse, but it was too late...

After the smoke cleared all I had left was one headlight and brakelights. I tried to replace the other headlight fuse and when I did the horn started honking and the fuse blew...

Fortunately I was able to limp home without getting in a wreck.

I've surveyed the damage. I actually traced the problem to one of those crappy ARB marker lights in the bumper; full of water shorted out.

I suppose I could try to repair the harness but there's so many damage circuits I think my best option is just to replace it. Won't be fun. Dash will have to come out, etc...

The moral of the story? Don't EVER use cheap fuses

 

[atomicshawn]

… Does anyone know where I can get a deal on a harness?

 

[Kernal]

Which harness burned, got a wider shot of the involved area?

 

[TDavidson]

Sorry man. That sucks.

Cruiserparts.net might have what you need. I ordered a rear window motor from them and got what I ordered.

 

[Reelitchy]

Sorry to hear x2
Thanks for the heads up on fuses. Never imagined anything like that

 

[atomicshawn]

Which harness burned, got a wider shot of the involved area?

I think 2 harness sections actually. Everything highlighted in red:

...via IH8MUD app

 

[TrickyT]

Shawn,
Good tip on bad fuses! Made in China perhaps? Littlefuse is a reputable made-in-USA brand. Based on your report, I'm tossing anything I have that doesn't say Littlefuse or didn't come from Toyota.

Maybe the highlighted section of the harness diagram is just confusing, but it looks like you're saying parts of the harness not located directly between the bad ARB marker light and associated fuse were burned too (ie., in the back part of the dash). This doesn't make sense to me. I can certainly see the wire connecting the headlight switch/circuit to the specific ARB marker light melting down, but are you saying wiring to engine sensors also melted?

Anyway, this could have ended up much worse then it did. Glad your 80 didn't go up in flames and thanks for alerting us to questionable quality fuses.

 

[NLXTACY]

… Does anyone know where I can get a deal on a harness?

Which harness? I have a spare brand new engine harness.

 

[half k cruiser]

For the headlight harness you could contact SMS, they can make whatever you want. I'm not sure on the others, guess you will have to call Beno or Dan

 

[Kernal]

Jason @cruiseryard is another possible option.

 

[atomicshawn]

Shawn,
Good tip on bad fuses! Made in China perhaps? Littlefuse is a reputable made-in-USA brand. Based on your report, I'm tossing anything I have that doesn't say Littlefuse or didn't come from Toyota.

Maybe the highlighted section of the harness diagram is just confusing...

Hey Tom. Made in China? I'm sure of it.

So the harness damage is obvious from the right front marker, along the front of the radiator, through a big connector under the engine compartment fuse block (the connector is actually melted together), under the abs unit, through the fire wall, through a major junction above the left kick panel, and up to the interior fuse panel. The other circuitry is highlighted only because it is all part of the damaged harnesses and will also be need to be replaced out of necessity, damaged or not. ...I hope that makes sense.

Which harness? I have a spare brand new engine harness.

I appreciate the offer. I actually have a spare engine harness too. Of course it's not one of the ones I need. I couldn't be so lucky. Thanks anyway.

Thanks for all the references. I'm hoping to pick up quality used. Cheap. Somebody parting one out. Willing to help a brother out, not trying to fund their kids college. Maybe I'll try posting in the WTB section...



...via IH8MUD app

 

[1973Guppie]

crazy but just a thought? isn't it more likely that there was some type of other wiring error besides the fuse? I mean the fuse metal element by just it's size should NOT be able to transport that much current. I am thinking the first time it warned you and the 2nd time something else was shorted and caused a bigger problem.

 

[Cruiserdrew]

Shawn,
Good tip on bad fuses! Made in China perhaps? Littlefuse is a reputable made-in-USA brand. Based on your report, I'm tossing anything I have that doesn't say Littlefuse or didn't come from Toyota.

The Littlefuse ones are ATO (open element) the Bussman are ATC (closed element). I thought the closed element would be desirable, and Bussman fuses I am pretty sure are still US made.

The cheap ones on the shelf in parts stores tend to be China copies, and by definition, useful only in emergencies and maybe not even then.

 

[OGBeno]

The front harness that goes for the headlights and includes the fusebox is one harness itself and separate from the engine harness.

PN: 82111-60323 and is still available from Toyota.

The other harness coming up to the fusebox then back through the fire wall and behind the instrument panel is the "cowl" harness and is one piece. Stupid expensive.

PN: 82131-6A493 and still available from Toyota.

 

[theside00]

Sign me up for two of those. I think we might need some spares at the shop.


Sent you a message back, I got some options for you.

 

[TrickyT]

I went through my fuse collection which includes Bussman ATC, Littlefuse ATO, and "generic." You can't see it in this photo, but both Bussman and Littlefuse have tiny raised lettering imprinted on the top of the fuse. The Bussman's say "BUSS ATC" and Littlefuse's say "LITTLEFUSE PAT.3909767." The generics don't have anything other then the amperage imprinted on the top, and even that isn't white lettering. The generics are all in the trash now.

Two on the left are generics, the 15A is Littlefuse, and the 40A is Bussman.

 

[ChiTown]

That sucks. I should have the harness out of my 95 this weekend, sounds like you may need a rear harness too since that's where your trouble started. Have you checked the rear one?

 

[LFD2037]

The front harness that goes for the headlights and includes the fusebox is one harness itself and separate from the engine harness.

PN: 82111-60323 and is still available from Toyota.

The other harness coming up to the fusebox then back through the fire wall and behind the instrument panel is the "cowl" harness and is one piece. Stupid expensive.

PN: 82131-6A493 and still available from Toyota.

Holy cow. $3,000 for the cowl harness!!!!!!!! That sucks. Thanks for the heads up on the fuses. I figured a fuse is a fuse is a fuse.

 

[NLXTACY]

Time to go look at my fuses

 

[atomicshawn]

I've been quoted $190 shipped for both harnesses by Colorado80. I'm liking this price. More than fair. Anyone know this guy? Always a little uncomfortable sending money to a stranger.


...via IH8MUD app