Wiring harnesses

[GoatWorthy]

I don’t know if this is a reasonable expectation without a complete frame off, but thought I’d search out the options and start researching.

I currently have the carpet up and plan to reupholster inside… before I do I started thinking - replace the interior wiring.

Not all the locks work and windows are struggling. Figured I’d rewire and clean up motors/tracks etc…

Is there a company that makes a new wiring harness for inside that’s plug and play?

Figure I’ll replace the engine bays harness when I get to that, but currently no issues forward of the firewall.

Thanks for aiding in my research and understanding

 

[ceylonfj40nut]

No. Best option is to look for a parts truck that has it or someone has pulled one. I am doing an engine swap where I face similar Qs. I just pulled my harness out (label each connector as you do so you can put it back), un-loomed it (removed all tape, held it together with zip ties to maintain its overall shape) and chased wires one by one to see if insulation is compromised or brittle. I was surprised at how good it was despite being old. I cleaned all connector pins with emory cloth glued to an ice cream stick and followed by contact cleaner. Where possible, i confirmed continuity from end to end. If wire was compromised, I grafted in new wire with Toyota splices. The harness has several ground blocks which need to be inspected to see if there are signs of burns or arcing. The one behind the instrument cluster is usually a culprit. I replaced any connector that was damaged with either new connectors or better ones from a scrap harness. I use Tesa Tape to reloom it as I go, cutting one zip tie at a time. This process gives you the peace of mind about gotchas from previous owner hack jobs. Make sure you have very good contact points for chassis or body grounds.

 

[cruisermatt]

x2 on everything @ceylonfj40nut said, with the exception that I would recommend actually de-pinnig any damaged wires from their connectors and actually replacing the entire wire from connector to connector rather then splices. All the terminals and correct color/stripe wires are readily available.

 

[Skniper]

Out of curiosity how does one go about sourcing the OEM wire colors?

 

[Malleus]

Yeah, what he said.

 

[cruisermatt]

Out of curiosity how does one go about sourcing the OEM wire colors?

Happy to get you what you need. I have pretty much all common LC color combos in stock in all the right gauges, as well as connectors, terminals, etc

 

[GoatWorthy]

Thanks for all the responses. Great write up @ceylonfj40nut.

So are the parts needed readily available if I dig into this? My fear is beginning it and finding something that I can’t readily replace.

Ay recommended upgrades while I’m here? Upgraded connectors etc…

Thanks

 

[cruisermatt]

Thanks for all the responses. Great write up @ceylonfj40nut.

So are the parts needed readily available if I dig into this? My fear is beginning it and finding something that I can’t readily replace.

Ay recommended upgrades while I’m here? Upgraded connectors etc…

Thanks

Yes, virtually all connectors, terminals, seals needed for a FJ60 harness are available. At least all the common ones that are needed. The best thing is to go over everything and make a list of what you actually need first, rather then just guessing.

 

[GoatWorthy]

Awesome. Really appreciate it.

I’ll just start by removing the door cards and pulling it all out then go over it as outlined.

I came across an old post in my search on a guy replacing all his connectors to Duetsch connectors.

Recommended or not? Is that something I can phase in or something that has to be done throughout all at once?

 

[Malleus]

There is no reason to replace the Sumitomo and Yazaki connector housings.

 

[CruiserTrash]

Out of curiosity how does one go about sourcing the OEM wire colors?

I'm testing out a few suppliers right now as I embark on completely scratch building an FJ40 harness. So far I like ProWire's TXL the best. Vintage Connections (small motorcycle wiring company) has some very quality striped wire in many of the Toyota-correct color combos, but only sell in pre-cut 10' lengths. I've tried to figure out where they're getting it and the best I can tell is GexPro ... but I can't find the same color options on the GexPro website. VC must be doing custom runs. WireBarn has some of the Toyota stripe combinations, but their wire feels kind of "cheap" for lack of a better description. Maybe it's that the insulation feels weird in my hand or the wire feels a little light for the gauge, I'm not sure. Lapp Tannehill looks like they might have some good wire as well, but you have to buy 1000' rolls at minimum, which isn't really cost effective for me doing a single harness. I would never use 1000' of each color of wire.

I used to be able to get a few solid colors of the real-deal new-manufacture Yazaki wire, but alas tariffs have made it not worthwhile. In 60 Series trucks Toyota used Furukawa and Yazaki wire to my knowledge. The new Yazaki I've gotten is really nice stuff.

In all of this. I haven't found a new production striped wire that isn't spiraled. The Toyota color stripes are straight across the length of the insulation. The spiraled stripe is easier to see from any angle though.