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The vehical has had several after-market electrical accessories installed, including a CB radio and off-road lights. The amateur wiring done for these installations has left a tangle of wires and a number of unreliable wire-connections . Sturdy connections and secure wiring is especially important for off-road vehicles , since the wiring will have to withstand rough road conditions, shaking, jarring , etc. The first task is to track down all of the wires to determine what each is connected to. Once that's done, the worn-out wiring can be replaced, and all of the accessory wires routed to a single fuse-panel. Once the electrical work is done, a winch will be installed on the vehical, making use of the new fuse box for its power supply.
Tools :
In addition to standard automotive-mechanic's tools, some of the specialty tools that will be needed for this project include new wires and terminals, split loom, zip ties, heat-shrink tubing and a heat gun. An air-ratchet is optional, but will help speed the assembly process.
Note :
- Always wear eye protection, and follow proper safety Note , when working with power tools.
- As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.
Wiring Inspection
- This vehicle has an old battery with multiple wires connected to the positive terminals - the product of multiple after-market accessories being previously installed. Accessories already installed include off-road lights, stereo amplifier, CB radio and alarm system. This has resulted in a tangle of wires under the hood, and an overloaded terminal on the positive side of the battery.
- Inline fuses have been installed in various locations, but at this point it's difficult to tell what the fuses and lines lead to.
- Some wires have become tangled and twisted, and some connections are simply taped or have come loose altogether.
- The wiring harness itself has become twisted and wrapped around some engine parts. Before the new winch can be installed safely, the wiring problems need to be addressed.
- As part of the electrical upgrade, a new and larger battery will be installed. Also , an accessory fuse panel will be added to accommodate and consolidate the wiring for all of the accessories, including the new winch.
- It's important to find a secure and safe mounting location for the new fuse box . The location must not interfere with other working parts, and must allow for wiring to be attached without causing problems. It should also be located close to the battery if possible, for least electrical resistance. For our fuse-box, we opted to mount it to the inner surface of the fender.
- Before beginning any electrical work, it's important to disconnect the cable from the negative side of the vehicle's battery. Make certain that you disconnect the cable from the negative side. Touching a metal wrench to the positive terminal could cause a dangerous arc, spark or even a battery-explosion.
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