1995 NAS 90 Main Wiring Harness Questions... - Defender Source
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Old April 4th, 2014, 12:52 PM
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Question 1995 NAS 90 Main Wiring Harness Questions...

Last summer we began 'restoring' my 1995 NAS Defender 90 I've had since we bought it in '95 ... and I think it's safe to say that the process feels like its costing just as much as we paid for the truck brand new (too scared to add up the numbers, lol).

We were in the homestretch of putting it back together, when the auto body shop that's working on it mentioned yesterday that there are major issues with the Wiring.

After some research online and in the forums, it seems that there's no quick/easy solution to replacing the Main/Rear Wiring Harnesses. I did contact Autosparks and, as mentioned in another forum post, they don't have one for a truck so 'young'.

I'm not sure what the right next move is, so I thought I turn to the folks that know a heck of a lot more than I do on these things...You guys!!!

Questions:
1) Is the best option to send it away to them to have it re-done or duplicated? It's 6-8 weeks . . . but was wondering if anyone familiar with Autosparks has heard of a faster turnaround (wishful thinking that maybe they underpromise on time, then perhaps overdeliver)

2) Is there anyone locally here in the US that can do a similar 'duplication'? Rovers North referred me to Painless Wiring, but the best they can do is a universal harness

3) When the harnesses do have to be swapped out, is that a job that an experience general mechanic can do . . .or, as the auto body shop recommended, does the D90's configuration make a 'electrical automotive' specialist necessary. How labor intensive is this?

I appreciate any suggestions or help on this. I just want to get this right.
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  #2  
Old April 4th, 2014, 12:58 PM
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What are the "major issues" with the wiring harness? As you probably saw in your searches, you can pull your harness(es) (as seen in a Chris Snell thread) and ship it/them out to be redone/duplicated. Aside from AutoSparks there are some places here in the US that will do it. It usually makes sense to have a few built if you go that route, and you can hopefully sell off the remainder to others in similar situations. A fellow forum member had told me of a friend of his who does this service, so maybe he'll chime in here.
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Old April 4th, 2014, 01:09 PM
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There are three big harnesses on a D90. The dash, the engine, and the rear. Which one is bad and how? My experience is faults are usually isolated (and common with known relatively easy solutions such as rotted rear light connectors on 95/95) if you did not have a fire.

What is wrong x2?
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Old April 4th, 2014, 01:32 PM
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The Main issue was the Harness coming from the engine > back into the main cabin. One of the heat shields, from what I'm told, seems to have come off, rusted off over the years and the wires were exposed to the engine heat. The outside of the wires were partially melted, but intact. It was driven fairly often before we dropped it off last fall, so it was def working. (although maybe I lucked out that there was no fire?)

They also mentioned the wires in the dash were "a mess and rusted out".

The rear harness should be ok, or at least they didn't mention it.

I figured if I was having the wiring redone, to just do them all in one shot.
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Old April 4th, 2014, 05:03 PM
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If I were doing the work on it, I would just fix the obvious issues, then once everything is together, see what is and isn't working. Its a lot of work to build a wiring harness. Its much easier to diagnose any electrical issues you might have, in my opinion.
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Old April 4th, 2014, 06:01 PM
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Quote:
Originally Posted by Jymmiejamz View Post
If I were doing the work on it, I would just fix the obvious issues, then once everything is together, see what is and isn't working. Its a lot of work to build a wiring harness. Its much easier to diagnose any electrical issues you might have, in my opinion.
X2 My experience is taking one apart ends up with a broken connector or two anyway. I can't believe the dash harness is "rusted" I mean maybe a couple connectors are corroded, but I would not be inclined to replace unless it had serious issues. As far as the melted part, if it ran before it may just need to be reinsulated. See if you can get a picture and we can advise further. New rebuild on all three harnesses would have to be a couple grand at least and you would probably end up with reused connectors anyway.

I have a used 95 D90 engine harness I have been hoarding if you get truly desperate, but I do not want to part ways with it if I can at all avoid it. (ie I am not letting it go cheap like most of the stuff I sell).
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Old April 4th, 2014, 08:25 PM
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@Jymmiejamz & Evilfij - thanks so much for the helpful advice fellas! I think if I combine your suggestions, I might be on my way to solving this without breaking the bank so much.
A) go get the harness from the shop and take a photo for opinions on its condition. Have the wires re-insulated if necessary and see how corroded the connections are.

B) Have them re-install it and go from there.

Evilfij, hypothetically speaking, if my engine harness is so far gone that it's unusable/unsafe, how much $ would you be willing to part with the '95 harness you have?

JSBriggs- I can only hope that that roll cage we ordered lines up as perfectly with the used SW hardtop. Ha, did I just say that something in a Defender lined might line-up perfectly? Dare to dream {Sadness}
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