Wiring Loom Removal - Create a Loop?

[FarFire70]

I've chased and removed the driver side headlight wiring back to the firewall.

If I go further to then remove this wire means I cut further into larger wiring looms on the firewall.

I plan to run a new wire to the driver side headlight anyway.

Rather than cut into and risk damaging the wires within the larger loom to remove this wire, I wanted to get an idea if I'm crazy just to crimp these wires together on the driver side.

And then crimp their end ends on the passenger side.

I know the full professional job is to completely remove these. I worry of accidentally damaging the remaining wires in the removal or just creating 10 times the work by just getting this cable removed and everything reloomed and taped.

If I crimp it together on both ends it just lives dead with in the wiring loom.

Thoughts?

 

[FarFire70]

Digging further... Looks like the loop would be in the dash, not the PDC...

Still hoping to not rip open the firewall harness but feeling may be more likely to trace back to the multifunction switch...

 

[Mike_H]

Why are you pulling them?

 

[MountaineerTom]

I don’t understand looping them together.

If you’re wanting to protect the wires from accidental contact with something or possibly corrosion, just put a small piece of heatshrink with internal adhesive lining on each end. While it’s still warm squeeze the end together with some pliers.

 

[NskLJ]

I've chased and removed the driver side headlight wiring back to the firewall.

View attachment 554403

If I go further to then remove this wire means I cut further into larger wiring looms on the firewall.

I plan to run a new wire to the driver side headlight anyway.

Rather than cut into and risk damaging the wires within the larger loom to remove this wire, I wanted to get an idea if I'm crazy just to crimp these wires together on the driver side.

And then crimp their end ends on the passenger side.

View attachment 554404

I know the full professional job is to completely remove these. I worry of accidentally damaging the remaining wires in the removal or just creating 10 times the work by just getting this cable removed and everything reloomed and taped.

If I crimp it together on both ends it just lives dead with in the wiring loom.

Thoughts?

What is the reason for replacing the wire? I have removed wires and just overlayed wires it really depends on the situation.

 

[hear]

I don't understand what you're doing, but if you chase that wire through the firewall you'll find that it is pinned into a huge connector under the dash. Were you planning on re-pinning this wire too?

 

[FarFire70]

Why are you pulling them?

What is the reason for replacing the wire? I have removed wires and just overlayed wires it really depends on the situation.

I wanted to clean up the wiring harness as much as possible. And to avoid future confusion if I leave and find the wire remnants.

I have over thought this problem...

I don't understand what you're doing, but if you chase that wire through the firewall you'll find that it is pinned into a huge connector under the dash. Were you planning on re-pinning this wire too?

Re-looking the wiring diagram, I suspect you are correct as I don't know how far back these wires go in the harness before they splice to a single wire back to the headlight stalk/switch.

No - Not interested to go so far that I'm re-pinning at the connector.

I don’t understand looping them together.

If you’re wanting to protect the wires from accidental contact with something or possibly corrosion, just put a small piece of heatshrink with internal adhesive lining on each end. While it’s still warm squeeze the end together with some pliers.

This is likely the approach I'll take.

Since I've gone this far to trace the wires back to the firewall, I'll cut them a foot or two off the firewall and use heatshrink to seal off the driver side wires and bury them in the loom.

My idea for the loop was to avoid a potential accidental grounding or cross-charging circuits situation, if the wires were completely isolated from any power source. I need at least one as a relay trigger so, as I realized, I over thought this 'problem'.

For the passenger side, I'll cut them back to where I'll use them to be the trigger for the new relays for the direct battery-to-headlight connection.

Appreciate everyone's comments on my attempt to over-engineer the 'problem'!

 

[hear]

i guess I still don't understand what problem existed that caused you to do all of this. If the wire is bad, cut it near the headlight plug, and then near the firewall, then properly splice a new one in? This seems like way more of a science project than what is necessary.

 

[FarFire70]

i guess I still don't understand what problem existed that caused you to do all of this. If the wire is bad, cut it near the headlight plug, and then near the firewall, then properly splice a new one in? This seems like way more of a science project than what is necessary.

I want to install a battery-to-headlight direct connection with a relay triggered off the stalk.

As I started working on it — honestly, I forgot/ignored some of the research I'd done on the wiring laydown.

From the below, I had thought the stalk wiring went to the passenger headlight and then over the grill (my bad assumption) to the driver side headlight.

Once I cut into the driver loom and realized the wiring ran down the fender... it became explorative surgery...

Way more work for myself caused by my curiosity and not stepping back in the moment.

 

[hear]

Maybe you should have lead with that. We're a helpful bunch if you let us know wtf you're trying to do.

 

[NskLJ]

I want to install a battery-to-headlight direct connection with a relay triggered off the stalk.

As I started working on it — honestly, I forgot/ignored some of the research I'd done on the wiring laydown.

From the below, I had thought the stalk wiring went to the passenger headlight and then over the grill (my bad assumption) to the driver side headlight.

View attachment 554850

Once I cut into the driver loom and realized the wiring ran down the fender... it became explorative surgery...

Way more work for myself caused by my curiosity and not stepping back in the moment.

I would have built an independent harness with high and low beam relays mounted on the core support then plugged into one of the headlight plugs to pick up the high and low beam relay triggers and the ground. Two wires back to the battery one high one low independently circuit protected. Then out put wires to each headlamp. Use 2 Bosch double pole relays (two 87 terminals) for ease of wiring.
https://www.amazon.com/Bosch-0332019150-Mini-Relay/dp/B004Z0W1LM/?tag=wranglerorg-20

 

[FarFire70]

I would have built an independent harness with high and low beam relays mounted on the core support then plugged into one of the headlight plugs to pick up the high and low beam relay triggers and the ground. Two wires back to the battery one high one low independently circuit protected. Then out put wires to each headlamp. Use 2 Bosch double pole relays (two 87 terminals) for ease of wiring.
https://www.amazon.com/Bosch-0332019150-Mini-Relay/dp/B004Z0W1LM/?tag=wranglerorg-20

That's what I'm planning to do. I was tossed for a loop (pun intended) when I started to pull the OEM wiring for the triggers...

Realized this question of creating a loop on the OEM wires was foolish, looking back. Got in my head on the project.

I've picked up the parts already. Went with Hella relays. Pulled parts off the basement self and moved them to the garage here:

Post in thread 'Building Homer (2005 TJ Build Thread)'

Aug 25, 2024

Cleaned up the workbench to work on the ARB and headlights. I have the Toyota H4 wiring harness but I already had parts to build my own wiring harness in hand and so I think I'm going to go with that to include a higher gauge wire.

Lesson learned is to check your parts when you get them...

I've had these parts in my stock for more years than I'm willing to admit. Having planned to get after this project sooner... So definitely out of warranty so I'll be ordering a new relay.

• FarFire70

• 

 

[NskLJ]

That's what I'm planning to do. I was tossed for a loop (pun intended) when I started to pull the OEM wiring for the triggers...

Realized this question of creating a loop on the OEM wires was foolish, looking back. Got in my head on the project.

I've picked up the parts already. Went with Hella relays. Pulled parts off the basement self and moved them to the garage here:

Post in thread 'Building Homer (2005 TJ Build Thread)'

Aug 25, 2024

Cleaned up the workbench to work on the ARB and headlights. I have the Toyota H4 wiring harness but I already had parts to build my own wiring harness in hand and so I think I'm going to go with that to include a higher gauge wire.

Lesson learned is to check your parts when you get them...

I've had these parts in my stock for more years than I'm willing to admit. Having planned to get after this project sooner... So definitely out of warranty so I'll be ordering a new relay.

• FarFire70

• 

If you can find a hella relay with 2 #87 terminals (vs 87 &87A) it makes the wiring easier as one wire goes to each headlamp vs splicing 2-1.

 

[C.J. Roberts]

I want to install a battery-to-headlight direct connection with a relay triggered off the stalk.

I would have built an independent harness with high and low beam relays mounted on the core support then plugged into one of the headlight plugs to pick up the high and low beam relay triggers and the ground. Two wires back to the battery one high one low independently circuit protected. Then out put wires to each headlamp. Use 2 Bosch double pole relays (two 87 terminals) for ease of wiring.
https://www.amazon.com/Bosch-0332019150-Mini-Relay/dp/B004Z0W1LM/?tag=wranglerorg-20

You guys do know that there are commercially made wiring harnesses that do exactly what you want, right? They are literally Plug and Play. It took me longer to decide where I wanted to run the wires than to connect it up.

https://www.amazon.com/Headlight-Harness-Toyota-Headlights-Problem/dp/B07B9QQMMH/?tag=wranglerorg-20

 

[NskLJ]

You guys do know that there are commercially made wiring harnesses that do exactly what you want, right? They are literally Plug and Play. It took me longer to decide where I wanted to run the wires than to connect it up.
View attachment 554883View attachment 554884View attachment 554888View attachment 554886
https://www.amazon.com/Headlight-Harness-Toyota-Headlights-Problem/dp/B07B9QQMMH/?tag=wranglerorg-20

View attachment 554883

I have not seen that, but that is exactly how I would build it.
(Edit) that is exactly what I would buy, I couldn’t build it for $25.
I have never looked for one actually.

 

[FarFire70]

If you can find a hella relay with 2 #87 terminals (vs 87 &87A) it makes the wiring easier as one wire goes to each headlamp vs splicing 2-1.

Good option but I already have stock on hand so I'll go with that, splicing them together.

You guys do know that there are commercially made wiring harnesses that do exactly what you want, right? They are literally Plug and Play. It took me longer to decide where I wanted to run the wires than to connect it up.
View attachment 554883View attachment 554884View attachment 554888View attachment 554886
https://www.amazon.com/Headlight-Harness-Toyota-Headlights-Problem/dp/B07B9QQMMH/?tag=wranglerorg-20

View attachment 554883

I have not seen that, but that is exactly how I would build it.
(Edit) that is exactly what I would buy, I couldn’t build it for $25.
I have never looked for one actually.

I bought the Toyota headlight set to get the glass headlights for extremely cheap as backup glass headlights. They include a wire harness that you'll see in the post on my build thread.

It's not 12g wiring and I would still have to modify it to make it custom. So savings maybe on the parts but not a custom install that I'm looking for on my Jeep.

 

[macleanflood]

Got to be careful because a lot of those cheap premade wiring harnesses use aluminum wire.

-Mac

 

[FarFire70]

Got to be careful because a lot of those cheap premade wiring harnesses use aluminum wire.

-Mac

I can't talk to the other aftermarket products.

But it does appear Toyota did use copper in their wire looms for their H4 upgrade.

Toyota did do a great job adding a lot of what appears to be dielectric or potting material on their connectors on all connectors...

But I pulled back the boot on the H4 connector and you can see in the above just above the 'n' in ground. It does show that this is copper. So good on them....

I'm not using this wiring but I've got it because of buying the glass H4 headlight kits.

 

[FarFire70]

Driver side sealed up

I'll post updates in my build thread from here on.