Frayed cable - How do I fix this? (Fixed!)
#1
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In the middle of doing a complete Intake Refresh/TP/WP project(s) in prep for SITM and found this last night:
![Name: IMG_0701.jpg
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This is the wiring harness that crosses on top of the water pump in front of the coolant crossover. I knew the outer jacket was separated, saw that when I replaced the water pump, but after I pulled the crossover last night, I found that the green ground wire was bare and missing about 1 inch of insulation. Good thing it's the ground wire, but obviously this needs to be fixed.
I'm thinking to use some kind of high temperature electrical tape to tape up the ground wire and then wrap the entire cable.
Any ideas where to get something like that or does anyone else have a better idea, short of replacing the entire wiring harness.
Thanks in advance.
![Name: IMG_0701.jpg
Views: 2123
Size: 58.2 KB](https://rennlist.com/forums/attachments/928-forum/443092d1274104894-frayed-cable-how-do-i-fix-this-fixed-img_0701.jpg)
This is the wiring harness that crosses on top of the water pump in front of the coolant crossover. I knew the outer jacket was separated, saw that when I replaced the water pump, but after I pulled the crossover last night, I found that the green ground wire was bare and missing about 1 inch of insulation. Good thing it's the ground wire, but obviously this needs to be fixed.
I'm thinking to use some kind of high temperature electrical tape to tape up the ground wire and then wrap the entire cable.
Any ideas where to get something like that or does anyone else have a better idea, short of replacing the entire wiring harness.
Thanks in advance.
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Last edited by underdog928; 05-18-2010 at 11:42 PM. Reason: Fixed it!
#2
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I'm in the middle of some intake work on my car, I discovered the wire in that harness that activates the starter was badly frayed. To the extent that I have no idea how the car ever started. All of the other wires were fine.
I pulled the harness, cut off all the sleeveing, added a new wire. If it's frayed there it might also be in bad shape further down the line. Just a question of how much work you want to do.
Pulling the harness wasn't that big of a deal, just connects to the starter, alternator, oil pressure and level sender.
What color is the frayed wire? Cannot tell from the pics.
I pulled the harness, cut off all the sleeveing, added a new wire. If it's frayed there it might also be in bad shape further down the line. Just a question of how much work you want to do.
Pulling the harness wasn't that big of a deal, just connects to the starter, alternator, oil pressure and level sender.
What color is the frayed wire? Cannot tell from the pics.
#3
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I'd recomend this stuff:
https://rennlist.com/forums/7572713-post25.html
http://www.google.com/products?hl=en...ed=0CCkQrQQwAg
I picked up a couple rolls at Harbor Freight
https://rennlist.com/forums/7572713-post25.html
http://www.google.com/products?hl=en...ed=0CCkQrQQwAg
I picked up a couple rolls at Harbor Freight
#4
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excellent. I am finishing my intake refresh and see some of those same wires with cracked insulation. was thinking about what to use to repair.
off to Habor Frieght....
off to Habor Frieght....
#5
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Hacker, it's the green ground wire that is frayed. All the other ones look ok. Actually the wire itself isn't too bad, only one or two strands are broken. I would probably run some solder on the open strands just to give them some added strength before closing it up.
Kurt: The self-fusing silicone tape .... BRILLIANT!
Thanks guys, that should do it.
Kurt: The self-fusing silicone tape .... BRILLIANT!
Thanks guys, that should do it.
#7
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Hacker, it's the green ground wire that is frayed. All the other ones look ok. Actually the wire itself isn't too bad, only one or two strands are broken. I would probably run some solder on the open strands just to give them some added strength before closing it up.
Kurt: The self-fusing silicone tape .... BRILLIANT!
Thanks guys, that should do it.
Kurt: The self-fusing silicone tape .... BRILLIANT!
Thanks guys, that should do it.
![Stick Out Tongue](https://rennlist.com/forums/images/smilies/tongue.gif)
If we are talking about the same wire, I found a small frayed portion too. Not until I started to pull off the entire sleeve did I realize the extend of the damage.
The self-vulcanizing tape is a must have in the tool box.
I used a combination of nylon sleeve, double wall self sealing heat shrink, and DEI heat sleeve to re-build this harness.
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#8
Drifting
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I'd recomend this stuff:
https://rennlist.com/forums/7572713-post25.html
http://www.google.com/products?hl=en...ed=0CCkQrQQwAg
I picked up a couple rolls at Harbor Freight
https://rennlist.com/forums/7572713-post25.html
http://www.google.com/products?hl=en...ed=0CCkQrQQwAg
I picked up a couple rolls at Harbor Freight
Any tips for using it correctly please?
#9
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color is why I hate trying to work elec issues. I am red/green color blind.
when I get in a jam on elec issues, I have my wife tell me which is which.![surrender](https://rennlist.com/forums/graemlins/surrender.gif)
I just replaced the 'green wire' from the distributor to the connector near the battery jump post. I told Roger when I got it that to me it looks orange.![Roll Eyes (Sarcastic)](https://rennlist.com/forums/images/smilies/rolleyes.gif)
on my '84 the 'green wire' was not part of this bundled group of wires. but I have no doubt there could be a green wire inside that bundle.
![crying](https://rennlist.com/forums/graemlins/bigcry.gif)
![surrender](https://rennlist.com/forums/graemlins/surrender.gif)
I just replaced the 'green wire' from the distributor to the connector near the battery jump post. I told Roger when I got it that to me it looks orange.
![Roll Eyes (Sarcastic)](https://rennlist.com/forums/images/smilies/rolleyes.gif)
on my '84 the 'green wire' was not part of this bundled group of wires. but I have no doubt there could be a green wire inside that bundle.
#10
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Must be a common failure; I have a spit in the exact same spot.
Blue tape on photo is to remind me to repair (plus a couple others):
Attachment 443103
Blue tape on photo is to remind me to repair (plus a couple others):
Attachment 443103
Maybe when, and if, I install electric fans, I'll be able to re-route that harness in front of the timing belt covers and eliminate the stress on it. Right now, however, it's got to go back from whence it came.
#11
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That area of the harness gets a lot of stress potentially. The wires slitting off vertically are to Temp2 and the temp sensor for the gauge. Plug wires from 7&8 are layered with the this harness under the thermostat cover, plus the harness is in the way of the lower bolt. The harness splits right there. Mine ran markedly better after tugging on the wire last week in frustration trying to get the thermostat cover off. I bet I have a break inside the insulation at the same place you show!
#12
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A little color blindness humor..... The winning Mega Millions lottery numbers are: 02 13 27 31 39, I know you will spend the money wisely
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#14
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BROWN is the typical ground wire colour used in the 928s.
As far as effecting a good repair you need to cut out all the bad and replace..............strip the jacket back do a good inspection before and after the break you can see, replace the wire with similar colour with a good solder joint then shrink wrap and cover with electrical tape.
As far as effecting a good repair you need to cut out all the bad and replace..............strip the jacket back do a good inspection before and after the break you can see, replace the wire with similar colour with a good solder joint then shrink wrap and cover with electrical tape.
#15
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Unless it's a last resort I will never use electrical tape anywhere on my car. Between the self vulcanizing 3M tape and heat shrink, there is no good reason to use electrical tape. It only melts and makes a mess after a while.
A good wire loom sleeve is cheap and readily available from McMaster Carr.
A good wire loom sleeve is cheap and readily available from McMaster Carr.