Hello XJs,
Got a screw caught in my dome harness and it fried all the way through the dash harness. At least four wires are melted together in various spots all the way down the main harness.
This is from a 96 XJ w/ some 211,000 miles on it. Man, I can be handy but this is a big job - and is it worth it? There's a few tools I'd need, about 4 connectors to replace, wire to buy etc....

I did find a guy locally who said I could bring it in for a fix quote....? (I've pulled the whole thing out from the dash)

Or, I finally tracked one down for sale, they'll pull it out of a 96 w/ only 88,000 (same year but less wear) miles on it for basically $500.

What would you do? - any feedback would be helpful.

Many thanks!

Andy.Raleigh

 

You can de-pin connectors with a paper clip if you study it and see how it's assembled. And the wires are just wires. Get some 18ga wire and go to town replacing the burned parts.

That's what I'd do.

 

Normally I would say get another one, check it out on the bench, and install it.
But not at $500.
Is this the one?

https://www.ebay.com/itm/14368802306...CABEgIYePD_BwE

 

Thanks for everyone's input. I saw that one Ralph77 - had some connectors that matched, some look iffy - I guess it was a different part of the transition year.
I'm not even sure but, from the picture it looks like they just lopped off the main connecting to the fuse box. Mine is kinda weird, manual trans and full electronics,
airbag - minus the seats (no pwr). Well, that one is listed as a Sport and mine is classic.

I guess I'm a bit overwhelmed here, I'd rather not spend the money of course. I'm gonna finish cleaning it all up before I make a decision.

Thanks for the tip agreen, I have yet to add a paper clip to my work table!

 

Does anyone know if the harness itself has a part number? Do I have to call the dealership for this info - or is it to old?
Still kinda shopping around for a new harness but, being the transition year I'm seeing some different stuff than I pulled out of
the dash. Had one guy tell me I need the part number. I have a later 96 as it was made in Aug.

Any help would be helpful!

Thanks,
Andy

 

https://xjjeeps.com/ has parts catalogs with numbers.

Got any pictures of the damage?

 

Wow, downloaded that - thank you agreen!
It did bring up some other questions. Mainly, why do some models have the fusebox on the passenger side?
Maybe it's not a 96 that does that but, I keep getting pictures of salvage sellers that don't quite match my own harness.

Also, from the .pdf on xjjeeps, what is the difference between the XJ and XJX1 body style? Couldn't find that one out
anywhere on the web...

I'll try to upload the damages in the next day or so. At least 4 wires are melted together at several points along the harness.
Near the far side it's really bad before it connects and chases up the pillar to the dome (also fried). There are many good parts
and some cabling left on it however, I've come to the conclusion that even if I took it somewhere professional to get it fixed,
they'd tell me to build a new one from scratch. I have a few good leads but, all the pictures don't look quite right.

++++
Thanks for that part number!! As I typed this I found the right one at the right price!
Highly recommend Jeremy at partsbreaker.com (aka the old Jeeps Unlimited)

 

500 bucks for four melted wires. No way! Id replace the four wires, now if the connectors are fine, simply cut and splice with solder some new wires. if connectors are also bad, buy a new connector or cut one off a wreck for use.
With the correct connector tool, it is easy to replace pins in a connector, but if plastic connector housing is melted then get a new or good used one.

next question, is not the dome light circuit fuse protected, and if so, why did the fuse not protect the wires? something sure aint right here.

 

Thanks robsjeep,
I didn't pay $500, thankfully! It's just that the four wires touched other wires in about 5 different places that take a lot of turns and stress.
There would have been so many splices it scared me to think about them bouncing around in the dash!
I still have a few connectors to replace and feel pretty confident that I now have most/all the parts for a working harness.

The dome light harness that connects to the main does run to several things on that fuse, in the box.
When the screw shorted the ground on that it blew the fuse. Then the youngster I bought it from started putting in lager fuses
to compensate and whole shebang kept melting at various parts of the harness all the way to the box.
It's hard to see at first but, the more you dig into fixing it the scarier it gets.

Now that you mention it, think I'll add an inline fuse in there so it can't ever happen again.

 

XJ and XJX1 might be for 2 door or 4 door. I don't know. 96 and 97 were weird years.