Rewiring

[jimmy_stikx]

So, I think I got a truck that was thoroughly abused in this department. I just want to know what is the general best way to go about rewiring one of these and if I'm going to need to take her down to the frame? About the only things that work are the ignition system, the head lights (wrong voltage btw), a and a taillight. I think the charging system works, but the wires for the alt and voltage reg are a rats nest (well, so is most of the wiring). Also, I have not really dealt with wiring harnesses before, though I kinda understand wire diagrams.

[52 M-42]

There are a lot of people here who have more experience and expertise in rewiring these trucks than I do, but, with that said, I've done it twice and it was far easier than I feared it was going to be. It is actually pretty straight forward. The first time I replaced mine as I tore out the old one and it was done in about 4 hours for the main harness. The wires are all numbered, and basically 2 goes to 2; 3b goes to 3b; etc.

If you want to replace all the clamps and clamp screws/bolts, replace the guts in the brake & marker lights housings, clean up the contacts on the breakers and instruments, etc it will take longer.

So, depending on the definition of "replacing the wiring harness" it can be fairly quick or more complex and take longer. The first time I just replaced the wiring harness and only replaced clamps or terminations as needed. The second time I was doing a complete re-manufacture of the truck starting with a bare frame. Two completely different jobs.

I should note that my truck was stock 24V.D.C. and I have kept it that way; thus I can use and trust the manual, with rare exceptions. If you are attempting to return a bastardized system to stock it's going to be a more complex project.

Good luck with your project!

If you can, post some pictures of your progress.

52 M-42

[jimmy_stikx]

For the sake of compatibility, I'm going to keep it 12v. I think for most of the frame wiring, the diagram should suffice, its the altenator and such I might have to use another manual for. I just order the industrial six manual from VPW, and I hoping it has a diagram for that....

I will definitely take pics, just can't guarantee how good they'll be as I only have a phone to take pics with currently...

[Cal_Gary]

Mine is also 12V Jimmy, and I installed a Painless Performance harness in mine (less the headlight switch, I'm using a civvy switch). Your multimeter and battery charger will be your best friends if you take this approach. Mine was spaghetti before I replaced the wiring, using the multimeter to confirm flow, and the battery charger on trickle for the functionality checks, so I didn't roast the new harness.... All works correctly except the fuel gauge and I believe that's my error-just haven't had time to troubleshoot it yet, but it worked when I finished the wiring install.
Gary