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1984 D100 Engine Wire Harness #3199582
12/23/23 09:29 AM
12/23/23 09:29 AM
Joined: Jan 2003
Posts: 1,792
Greer, SC
TooMany62s Offline OP
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TooMany62s  Offline OP
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Greer, SC
I replaced the lean burn slant six in my '84 D100 with a 440 more than thirty years ago. The wiring of the engine harness has become brittle over time. Of course the harness is no longer produced. Does anyone know where I might find a decent used harness. My guess would be any old harness has the same problems as mine. Any suggestions on what to do?

thumbnail_IMG_2536.jpgrebuilt engine.jpg
Re: 1984 D100 Engine Wire Harness [Re: TooMany62s] #3199666
12/23/23 04:10 PM
12/23/23 04:10 PM
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ILLINOIS
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volaredon Offline
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I got lucky at a local junkyard when I had to redo my 85.

Re: 1984 D100 Engine Wire Harness [Re: volaredon] #3199797
12/24/23 10:33 AM
12/24/23 10:33 AM
Joined: Sep 2003
Posts: 19,396
north of coder
moparx Offline
"Butt Crack Bob"
moparx  Offline
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all jokes aside, if your connector [plastic] pieces are in good condition, a handful of quality brass connectors, a good crimping tool or two, and a few spools of the correct color wire will easily duplicate a harness for a fraction of the cost of a reproduction harness.
it's not as hard as one would think, just take your time and be patient.
get extra terminal ends and practice on several chunks of junk wire until you get the crimping process down.
beer

Re: 1984 D100 Engine Wire Harness [Re: TooMany62s] #3199940
12/25/23 08:30 AM
12/25/23 08:30 AM
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Oregon
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earlymopar Offline
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Oregon
Great looking truck.

What I would look to do if I was in a similar situation and wanted to retain a factory harness is to get an original harness and use it as a pattern for copying and making a new one. That way you can take your time to make it correct and you can keep driving your truck until you're ready to make the swap. This would also reduce the time your truck is down.

Re: 1984 D100 Engine Wire Harness [Re: earlymopar] #3199974
12/25/23 02:37 PM
12/25/23 02:37 PM
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ILLINOIS
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volaredon Offline
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Yup.
The original harness off of my 85 was the worst butchered harness I'd ever seen.
The alternator wire was twisted and taped, changed colors and gauge size 3x in the length of the/6 valve cover, with bare strands hanging out of the tape job. One dangling within an inch of the fuel line to the carb. A lot of house wire, a lot of fried fusible links.... I went to the junkyard and got another, and undid all the original tape and went thru the whole thing closely/ I found a few suspect areas which I fixed with crimps solder and heat shrink. I also did away with every fusible link, instead I found an under hood fuse box from "something else" and wired everything that was previously run thru a fusible link to/thru that.
Its beyond me, what they were thinking when they decided to wire everything thru softer wire 3 gauge sizes smaller than the parent circuit, and the way they crimped it into the harness to where it couldn't be properly replaced if and when it cooked.

Re: 1984 D100 Engine Wire Harness [Re: TooMany62s] #3200031
12/25/23 11:36 PM
12/25/23 11:36 PM
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UPPER MICHIGAN, MARQUETTE COUN...
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NITROUSN Offline
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Originally Posted by TooMany62s
I replaced the lean burn slant six in my '84 D100 with a 440 more than thirty years ago. The wiring of the engine harness has become brittle over time. Of course the harness is no longer produced. Does anyone know where I might find a decent used harness. My guess would be any old harness has the same problems as mine. Any suggestions on what to do?


So your 84 harness has already been modified for a big block. If your bulkhead is good then just buy wire and make a new one. Its the engine harness so there is only about 8 wires.

Last edited by NITROUSN; 12/25/23 11:38 PM.
Re: 1984 D100 Engine Wire Harness [Re: NITROUSN] #3200467
12/28/23 12:41 PM
12/28/23 12:41 PM
Joined: Sep 2003
Posts: 19,396
north of coder
moparx Offline
"Butt Crack Bob"
moparx  Offline
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i have been using marine grade heat shrink with the "glue" when heat shrink is required, for quite a few years now.
i highly recommend it.
beer

Re: 1984 D100 Engine Wire Harness [Re: moparx] #3200537
12/28/23 07:07 PM
12/28/23 07:07 PM
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ILLINOIS
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volaredon Offline
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Yup agreed when it can be found.
The normal stuff from the hardware store sucks

Re: 1984 D100 Engine Wire Harness [Re: volaredon] #3200691
12/29/23 01:55 PM
12/29/23 01:55 PM
Joined: Sep 2003
Posts: 19,396
north of coder
moparx Offline
"Butt Crack Bob"
moparx  Offline
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north of coder

Re: 1984 D100 Engine Wire Harness [Re: moparx] #3200859
12/30/23 09:11 AM
12/30/23 09:11 AM
Joined: Jan 2003
Posts: 1,792
Greer, SC
TooMany62s Offline OP
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TooMany62s  Offline OP
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Greer, SC
It looks like the answer is: Make One. So, I'll give that a shot. Thanks!!

Re: 1984 D100 Engine Wire Harness [Re: TooMany62s] #3201123
12/31/23 01:06 PM
12/31/23 01:06 PM
Joined: Sep 2003
Posts: 19,396
north of coder
moparx Offline
"Butt Crack Bob"
moparx  Offline
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Joined: Sep 2003
Posts: 19,396
north of coder
making one is not as hard as it is intimidating.
use quality wire [automotive grade] and quality terminals, crimped with the proper crimping tool, and take your time.
you will do a good job.
beer

Re: 1984 D100 Engine Wire Harness [Re: moparx] #3201331
01/01/24 06:10 AM
01/01/24 06:10 AM
Joined: Jan 2003
Posts: 1,792
Greer, SC
TooMany62s Offline OP
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Greer, SC
Originally Posted by moparx
making one is not as hard as it is intimidating.
use quality wire [automotive grade] and quality terminals, crimped with the proper crimping tool, and take your time.
you will do a good job.
beer


Where can I find the correct terminals?

Re: 1984 D100 Engine Wire Harness [Re: TooMany62s] #3201509
01/01/24 10:51 PM
01/01/24 10:51 PM
Joined: Jul 2007
Posts: 4,911
Wills Point, Texas
Hugh Jorgan Offline
master
Hugh Jorgan  Offline
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Posts: 4,911
Wills Point, Texas
Digikey. thumbs

Re: 1984 D100 Engine Wire Harness [Re: Hugh Jorgan] #3201665
01/02/24 02:13 PM
01/02/24 02:13 PM
Joined: Sep 2003
Posts: 19,396
north of coder
moparx Offline
"Butt Crack Bob"
moparx  Offline
"Butt Crack Bob"

Joined: Sep 2003
Posts: 19,396
north of coder
digikey indeed ! up


Digikey
https://www.digikey.com


beer







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