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  #1  
Old October 10th, 2015, 04:20 PM
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Samer Hijazi
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Disaster Averted

Having just completed the engine swap from a 3.5 to a 3.9, and installed an NRP exhaust, earlier this morning I took my '86 D110 out on the road for the 1st time, only to be greeted by a small electric fire under the hood. I was able to quickly put it out with a fire extinguisher I carry on board. There were three wires that caught fire, and I was lucky nothing else got destroyed.

I traced the fire back to a short in the wire that goes to the fuel pump, which had apparently melted due to its proximity to the catalytic converter. It looks to be the only wire that melted, I am yet to find out, and there lies the problem.

This wire is in a harness that goes into the chassis and runs all the way to the back. The right side catalytic converter is right there, with about an 1/8" gap, that's it!

Short of removing the exhaust system in order to get to the entry point in the chassis, pulling this whole bundle out and rerouting it, is there another solution out there? Has anyone run into this issue, and if so, how did you solve it?
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  #2  
Old October 10th, 2015, 04:26 PM
javelinadave
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Glad you avoided a disaster. At this point I would pull a wire thru the frame and splice it into the harness up front and put a fitting so it plugs into the fuel pump. That way it is well protected and only has one splice. Make sure you heat shrink the splice and wrap it well afterwards.
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Old October 10th, 2015, 06:11 PM
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Are you running the harness through a hole that is between the frame rails or the one that's on the outside? The harness on NAS trucks enters the frame on the outside (opposite) the cats. If you ran the harness thru the hole on the inside of the frame rail- that's your problem
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  #4  
Old October 10th, 2015, 06:47 PM
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Samer Hijazi
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I didn't run the harness myself, my truck is an '86 ROW, and the harness is between the frame rails.

How much of a PITA is it to pull it and re-run it on the outside?
Is there a better alternative? Would a heat shield work?

This one is Titanium, and supposedly good up to 1,350 degrees.
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  #5  
Old October 10th, 2015, 07:19 PM
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Quote:
Originally Posted by One Ten View Post
Are you running the harness through a hole that is between the frame rails or the one that's on the outside? The harness on NAS trucks enters the frame on the outside (opposite) the cats. If you ran the harness thru the hole on the inside of the frame rail- that's your problem
Sam....totally off topic, but what rear trailing arms are those?
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  #6  
Old October 10th, 2015, 08:13 PM
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That's a Terra Firma front radius arm in the pic. Running the harness thru the frame is easy if you have electrician's fish tape. Fish it thru the frame, tape the new harness to it and pull it thru.
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  #7  
Old October 13th, 2015, 01:14 AM
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Samer Hijazi
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Disaster Averted

Problem solved. The truck is up and running again. I didn't have to fish the entire harness out then back in. I disconnected it at the fire wall, drilled a new hole in the chassis on the same side, about 2 feet back (towards the back of the truck), and fished the harness out. I ran it on top of the chassis rail back to its location under the hood.

It now sits at least 6 inches away from any exhaust pipes, wrapped in fabric tape. Attached are some pics I took, including one with the wire that melted and made contact with ground.

Finally, I recommend that everyone carry a good fire extinguisher at all times in their vehicle. Mine saved my truck!Click image for larger version

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1997 P38 Vitesse (Red)
2003 Discovery II
Defenderless, for now!
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