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5/04/2020 7:00 PM  #1


Firewall to headlight harness replacement questions

So in my quest to get my Mustang started I have found a new problem I need to conquer. The firewall to headlight harness is burnt to a crisp. I've also found several hacks in the harness where it wasn't burnt. I'm hoping my abilities are up to the task to replace this. At some point down the road I will seriously consider rewiring the whole car. I've done several searches and a lot of research. Does anyone have any experience replacing this? Or any opinions on what harness is the best to get? I'm leaning on purchasing one of the following;

CJ Pony Parts - https://www.cjponyparts.com/cj-classics-headlight-wiring-harness-usa-made-1967/p/WHL4A/

John's Mustang - https://johnsmustang.com/products/1967-mustang-firewall-to-headlight-wire-loom-without-tach-without-gt?variant=25080361189440

MAC's - https://www.macsautoparts.com/ford_edsel/ford-mustang-firewall-to-headlight-wiring-all-cars-without-tachometer-or-factory-fog-lights.html

Any info you can provide is greatly appreciated.

Thanks
 

 

5/04/2020 8:08 PM  #2


Re: Firewall to headlight harness replacement questions

More vehicle info please. That battery tray looks pretty bad, what kind of shape is the rest of the car in.
The wires might not be your worst issue.
What are your long range plans for the vehicle.

Last edited by Rudi (5/04/2020 8:19 PM)


Good work ain't cheap, Cheap work ain't good!   Simple Man
 

5/04/2020 9:00 PM  #3


Re: Firewall to headlight harness replacement questions

I replaced mine a couple of years ago and it was easy.  Get a good one from a good supplier.  I got mine from Mustangs Plus.  It should be an exact duplicate of what you have.  No extra this's and that. The wire colors must match what your owner's manual says they are.  It will save you many headaches later on.  And, there are a lot of crap ones, so be careful.

First trace all the wires in your current harness without changing their location. 
Lay out the new one next to the old, wire by wire to verify what goes where.
Then un plug at the firewall and plug in the new one.
Replace each wire in whatever order fits best for your layout.
Make sure the battery is disconnected before you begin.

Mine only took an hour or so.


Original owner - 351w,T-5, 4whl disks, power R&P
 

5/04/2020 10:44 PM  #4


Re: Firewall to headlight harness replacement questions

Also check the other side of the firewall, I'd be surprised if the damage was only in the engine bay.
How far up the harness did it burn? Do the wires look burned at the firewall end?

Last edited by 50vert (5/04/2020 10:51 PM)


"Those telephone poles were like a picket fence"
 

5/05/2020 5:20 AM  #5


Re: Firewall to headlight harness replacement questions

With 90% of the wiring harnesses for these cars reproduced its never a bad idea to replace everything.  Just make sure that you select all the correct options your car has when ordering them.  Then verify they are the same, as recommended.  Its almost impossible to screw up the installation, except, if the car won't start afterwards you've probably swapped the reverse lights and neutral safety switch plugs.  They are the same plug and right next to each other on some models.  I did that at least twice over the years. 

I look at it this way, I'm replacing a lot of the wiring on my '89 GT, a car that's 20 years newer.  The wiring is brittle, the plugs are broken, etc.  For wiring I'm a believer in if its available go new. 

 

5/05/2020 6:45 AM  #6


Re: Firewall to headlight harness replacement questions

My question was to find out if you want to keep the car stock or to do modifications that need more than stock wiring.
If the rest of the wires in the car are in the same condition as the one you pictured, you may have to replace all the car’s wiring. If that is the case the cost involved will be far greater than going to a complete replacement such as the one that American Auto Wire sells.


Good work ain't cheap, Cheap work ain't good!   Simple Man
 

5/05/2020 10:20 AM  #7


Re: Firewall to headlight harness replacement questions

Adding two bits - generally speaking, National Parts Depot has the best quality parts and the very best customer service.  Out of the thousands of dollars I have spent with them I have been disappointed with their stuff once, and it was promptly replaced when I contacted them.


Founding Member of the Perpetually Bewildered Society
 

5/05/2020 10:41 AM  #8


Re: Firewall to headlight harness replacement questions

I've heard good things about AAW.  I elected to just use replacement harnesses and modify the harnesses where I needed.  I added relays for the headlights (that's basically a must if you want to use modern bulbs), added an electric fan, added modern gauges, added a modern audio system, and will soon be adding power windows.  The thing I like is that the circuits I didn't touch still have all the stock color wires, plugs, etc.  This allows me to easily use factory diagrams and schematics in future troubleshooting.  If you plan to add a lot more electrical items now or in the future I would suggest both upgrading your alternator to a 3G, and consider adding an auxiliary fuse block to make tying in accessories clean and easy. 

I'll second John's advice to use NPD as a supplier.  I've never been unhappy with them and I've bought parts for both my '67 and my '89 from them.  I actually found a couple of NOS parts there at reasonable prices.  With the closing of Mustangs Unlimited they will now be my go to supplier for the '67, and I'm sure I'll buy more stuff for my '89 there too, though for late models LMR is really hard to beat if they have the parts you're looking for. 

As far as abilities, you'll learn.  That's what we all did.  Electrical is typically the least intuitive for all but those who have an electronics background.  Just take your time, be patient, and ask for help.  The good news is these cars are very simple electrically, so they are good to learn on and easy to troubleshoot. 

 

5/05/2020 12:18 PM  #9


Re: Firewall to headlight harness replacement questions

Made in USA. ( I selected no tach or fog lights, like a couple of your links.)
https://www.lectriclimited.com/forward-lamp-harness-101961

 

5/05/2020 12:51 PM  #10


Re: Firewall to headlight harness replacement questions

Even though the AAW kit is a major undertaking it could be the best route. 
 The kit eliminates all the decades old brittle wires, impossibly hard connector plugs, corroded bulb sockets, worn out ignition, headlight, wiper switch etc.  One or more, or all of those will eventually cause you grief. the kit also comes with a relay bank for headlights and other accessories.
As for colour coded wires, it's a non issue, each wire in the kit is individually marked for it's function and  the wire diagrams from AAW are in techicolour,  far superior and  easier to read than the microscopic black and white schematics in the Ford shop manual.
 All in all the AAW kit is not difficult just time consuming.
 Also note the AAW kit does not support an external voltage regulator, you will need a 3g Ford or a single wire alternator which as well a great upgrade.


Good work ain't cheap, Cheap work ain't good!   Simple Man
 

5/05/2020 2:59 PM  #11


Re: Firewall to headlight harness replacement questions

another source and  great place for any custom add ons  

https://www.ynzyesterdaysparts.com/    

 

5/05/2020 4:20 PM  #12


Re: Firewall to headlight harness replacement questions

If you want to stay stock, look at;  midlifeharness.com
 They have a good reputation on Mustang wire harness retoration.


Good work ain't cheap, Cheap work ain't good!   Simple Man
 

5/05/2020 7:32 PM  #13


Re: Firewall to headlight harness replacement questions

I used Midlife for my stuff. Randy is a great guy, does outstanding work, and has reasonable prices.


Bob. 69 Mach 1, 393W, SMOD Toploader, Armstrong  steering, factory AC.
 

5/05/2020 8:17 PM  #14


Re: Firewall to headlight harness replacement questions

Randy is The Man for under dash wiring. He doesn't recommend re-working under hood wiring.
For them, buy new, I think the Alloy Metal brand is the best. NPD has the brand.


"Those telephone poles were like a picket fence"
 

5/31/2020 7:20 AM  #15


Re: Firewall to headlight harness replacement questions

Thank you for all of your suggestions and wisdom. My current plan is to just get the car running, Down the road I'd like to make it a nice cruiser/daily driver. I'd like to get a 347, 5 speed and have a few modern convinces like disc brakes, power steering, LED or halogen lights and a decent bluetooth radio. Over the weekend I decided to attempt changing out the firewall/headlight wiring harness. I ended up using a wiring harness from CJ Mustangs. I was shocked at how easy it was to replace this harness. The wiring under the dash was supple and looks to be in good shape. The only real problem/disappointment I have with the harness install is that the wires which go to the horns seems to be about 2 to 3 inches to short. However what I did uncover has me coming back to the board and asking for more help. It seems that the PO cut into the alternator harness and directly soldered the alternator harness into the firewall/headlight harness (see the blue wire in the attachment.)  I've heard of the 3 to one wire alternator mod, but I have no idea if this is what that was. If you look closely you can see that the wire is burnt for about a good foot after this mod. From what I'm told, the father of the previous owner connected the battery backwards after using the battery to jump a riding lawn mower, the PO saw smoke coming from the engine bay and disconnected the battery. The car has been in storage until I acquired it. I've attached pics of the alternator, there were two connections with boots that covered the connections and two ring terminals. In all of the alternator harnesses I've looked at on line, none resemble what I have, the one that came closest to resembling mine was for a big block. I think the car currently has a 289 installed. I did remove the alternator and I'm not sure if it is original to the car. When I spin the pulley/shaft it spins freely but does have forward to backward play in it.  So I'm thinking of replacing the alternator. So my question, if I replace the alternator what should I go with? Does it make sense to go with an alternator with more amperage? If I do this does the wiring change?
 

     Thread Starter
 

5/31/2020 7:36 AM  #16


Re: Firewall to headlight harness replacement questions

My advice would be to get the correct alternator harness for the car.  That's your best starting point.  Its supposed to plug into the main harness.  I would not change that.

After that, now that you are starting where you would have if the car didn't have a hacked up electrical system, I would advise converting to a 3G alternator.  This is especially important if you plan to add modern conveniences to the car like a better stereo, power windows, etc. 

There are alternators billed as being "1 wire".  Frankly they don't work terribly well, and 1 wire is really a misnomer.  Here's a link to a good wiring diagram for the conversion:

https://www.stangnet.com/mustang-forums/threads/3g-alternator-conversion.802741/

 

5/31/2020 9:12 AM  #17


Re: Firewall to headlight harness replacement questions

- wire harness pic I referenced above (blue wire reference).
- connections to the alternator.
upload picture to web - back of alternator.
- the only numbers I could find on the alternator.

 

     Thread Starter
 

5/31/2020 9:57 AM  #18


Re: Firewall to headlight harness replacement questions

That's an old style externally regulated alternator.  Not the original, which would have been an Autolite.  They were ink stamped on the side originally. 

I'm trying to figure out what the wire butcher did to that harness, but as his lack of skill/knowledge leaves me stupified I'm going to stop. 

I can tell what the wires are supposed to do.  The wire missing a ring terminal with the rubber hood on it was for the red post on the alternator.  That's the primary charging wire.  The smaller wire missing the ring that has the large rubber cylinder molded onto it went to the other terminal with the plastic ring.  That's the wire that goes to the regulator.  The one with the large ring is a ground that should go to the block where the ground cable bolts from the battery.  That fourth wire is also a ground that goes to one of the alternator case bolts.  Do not connect it to the stator terminal or the car won't charge (yes, I learned that the hard way as a kid). 

The three wire molded plug should be for the alternator harness.  Here's the right alternator harness for your vehicle:

https://www.cjponyparts.com/cj-classics-alternator-wiring-harness-usa-made-without-tachometer-6-cylinder-v8-small-block-1967-1968/p/WALT4F/

I'd just buy that and install it correctly and not worry about what daddy dip#$%^ did before you.  I definitely wouldn't try to copy his hackery on your new harness. 

 

5/31/2020 10:21 PM  #19


Re: Firewall to headlight harness replacement questions

FYI.........I bought my 'chrome-plated' alternator from Skip White performance for a super good price and its got a LIFE-TIME guarantee! I have had it several years and no issues (except the chrome is peeling off...........but I live at the beach soooooo... ) The price was less than what I could buy it for at Poop Boyz using my employee discount!!
Jus say'in!
6sal6


Get busy Liv'in or get busy Die'n....Host of the 2020 Bash at the Beach/The only Bash that got cancelled  )8
 

Board footera


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