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Old 03-05-2012, 07:02 PM   #1 (permalink)
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71 Scout II - Gutting the electrical this weekend

Lurked for awhile, searched a lot, didn't have much to post until now. Replacing the wiring and alternator in the Scout this weekend. Went with the EZ Wiring Mini 20 and a 120 amp alternator. If nothing else, the entertainment value of the wiring mistakes should be worth something.
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Old 03-05-2012, 07:04 PM   #2 (permalink)
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Great job!
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Old 03-05-2012, 07:07 PM   #3 (permalink)
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Not done, just starting. Pictures will be forthcoming.
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Old 03-05-2012, 07:26 PM   #4 (permalink)
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Cool story Bro.
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Old 03-05-2012, 08:25 PM   #5 (permalink)
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Don't pull out the green wire. You'll never get the thing started again if you do
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Old 03-05-2012, 08:30 PM   #6 (permalink)
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Cool story Bro.
Word.
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Old 03-05-2012, 11:22 PM   #7 (permalink)
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When you have done about 20 you get it down to a science, you need to use a 12 circuit harness. The 20 has way more than you will need, I did Leona's with a 21 circuit but it has power windows, power locks, seats and seat heaters ect. Check out Tony's Scout on BP or HCS Scout here and there will be lots of info on the wiring.
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Old 03-06-2012, 04:55 AM   #8 (permalink)
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Thought about the 12, but went with the 20 because I wanted to have extra circuits for offroad lights, on board air, winch, stereo, etc. This is my first time through a complete re-wire, so I am assuming lots of pictures, swearing, and beer. It's so Franken-wired right now that nothing inside the engine is recognizable. Didn't think about BP, but I did find the links on here. Hoping to add mine to the knowledge base.
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Old 03-06-2012, 09:24 AM   #9 (permalink)
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Those cheap harnrss are not really frendly for the off road acc.

Take it one step at a time ie. tail lights, head lights (make sure you have the horn with the head light harness), then engine, then interior. You will have to add wires for the heater motor speed circuit, and for the windshield wiper motor and sprayer, (the harness will only supply power to the switches) HTH
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Old 03-06-2012, 09:53 AM   #10 (permalink)
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Hoping to add mine to the knowledge base.
Best first posts for a noob I've read in a while. Some of the other tuesday guys were missing this point good job man.
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Old 03-06-2012, 12:43 PM   #11 (permalink)
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Those cheap harnrss are not really frendly for the off road acc.

Take it one step at a time ie. tail lights, head lights (make sure you have the horn with the head light harness), then engine, then interior. You will have to add wires for the heater motor speed circuit, and for the windshield wiper motor and sprayer, (the harness will only supply power to the switches) HTH
Hadn't thought about the performance of the offroad accessories. Will need to rethink some of the plan. Hadn't thought about the horn with the lights (don't know why). I do have plans to do wire salvage on the switches, heater, and wiper motor that I picked up on one of my searches. Planning on two full days, or about 24 hours, which means I can double it for the real time.
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Old 03-06-2012, 12:50 PM   #12 (permalink)
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Best first posts for a noob I've read in a while. Some of the other tuesday guys were missing this point good job man.
Thanks. Can't stand the,"what kind of _______ came stock on a 19-- Scout...?" Google works wonders, as does the service manual. When that fails, improvisation, spare materials, and a heat source works wonders to solve most issues.
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Old 03-06-2012, 01:19 PM   #13 (permalink)
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I'm about to rewire also, this should be fun to watch.
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Old 03-10-2012, 06:45 AM   #14 (permalink)
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Day 1

Starting today around noon. Today's line-up:
1. Remove old wiring and alternator (probably the most enjoyable task), taking pictures to document what was there.
2. Layout of new harness, grouping of wires, and initial split loom
3. Document anything that isn't going to the label on the wire

Initial parts list:
-EZ Wiring 21 circuit mini harness
-120 amp alternator
-30 feet of 3/4 inch loom
-30 feet of 1/2 inch loom
-50 feet of 1/4 inch loom
-1 roll each of black, white, and red 10 gauge wire
-2 rolls of electrical tape
-1 jar of liquid electrical tape
-1 Scout II service manual with wiring diagrams
-150 amp main bus (marine grade)
-1 tube of dielectric grease
-1 assortment of terminal connectors
-2 boys to "assist" in the work
-1 camera to document the carnage
-1 sheet of paper to write down the crap I forgot and the amount of beer I will need to finish.

I will post pics tonight of the original wire, as there are some creative approaches to automotive wiring under the hood. The term Southern Engineering keeps coming to mind....
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Old 03-10-2012, 04:05 PM   #15 (permalink)
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Day 1 - Post Mortem

1. Laying out all the stuff - good idea.


2. Getting under the hood and really seeing what a mess it was - enlightening. My favorite part is the alligator clips.

The rain got the best of me today. I made the progress that I could, but reached a point that the rain just got to be too heavy. Removal is going slower than expected, largely due to the creative way that previous owners have wired/tied in/spliced.

Progress today:
1. Unpacked supplies
2. Removed battery and alternator
3. Removed engine harness wiring
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Old 03-10-2012, 09:55 PM   #16 (permalink)
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I did the same harness EZ wire 21 circit it took me about 3 days but my scout was half way apart and had no wiring at all when i started good luck
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Old 03-11-2012, 05:12 PM   #17 (permalink)
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Day 2 - Post Mortem

Observations
1. I never knew you could have splices of splices of splices
2. Someone had a surplus of green wire, as all of the Southern Engineered sections were green
3. So far, the harness has been pretty straight forward. way too much wire in the front, not sure how much extra will be in the back.
4. Beginning to realize why I was having some of the issues I was. Lots of wiring on its last legs.
5. I removed about five pounds of dirt from the right rear quarter. Not sure how you get that much dirt that high in a vehicle.

Progress since yesterday:
1. Wiring removal complete
2. Wiring bundled
3. Engine and rear wiring groups initial pull completed
4. First set of looming on

No real pics of today's work. Looks like the jumbled mess it did yesterday. Plan on posting the completed engine compartment tomorrow.

Total time spent - 8 hours over two days
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Old 03-12-2012, 03:05 PM   #18 (permalink)
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Day 3 - Post Mortem

Observations
1. Creative wiring choices by previous owners continue to amaze me
2. The International Service Manual is a must have. There are wires on the harness that look important, but aren't used. Without the service manual, there isn't a way to know.
3. The EZ Wiring Manual is written for anyone to use, which means there isn't anything specific enough to help with a Scout.
4. Half days are productivity killers. I have a day free of other commitments tomorrow, so I should be able to take a full run at it.

Progress since yesterday:
1. New alternator installed
2. New coil installed
3. Engine wired

Total time spent: 12 hours over three days.

Pictures:

New Hot Bus


New Coil


New Alternator


Conduit Mounts to hold the loom (gotta have a little Southern Engineering)
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Old 03-12-2012, 04:41 PM   #19 (permalink)
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When I do Scout IIs I run the rear wiring out the factory hole where the head light connector was and then into the frame there is a hole where you can bring out the tranny wires Rev lights and another for the fuel gage, then the tail lights out the back of the frame. This keeps the wires out of harms way just insure all your welding is done Also when I do the frame offs I run the fuel lines down the other side in the frame. HTH
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Old 03-12-2012, 07:14 PM   #20 (permalink)
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What kind of harness you been using, Robert? Just curious?
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Old 03-12-2012, 08:59 PM   #21 (permalink)
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When I do Scout IIs I run the rear wiring out the factory hole where the head light connector was and then into the frame there is a hole where you can bring out the tranny wires Rev lights and another for the fuel gage, then the tail lights out the back of the frame. This keeps the wires out of harms way just insure all your welding is done Also when I do the frame offs I run the fuel lines down the other side in the frame. HTH
I have welding I have to do, but no time soon. I saw the frame on the passenger side had holes, but didn't check the driver side. Will do that tomorrow. The wires are jacked in the original holes, so I can either route down the outside and mount (makes it easier to weld), or try down the driver-side frame. None of the tranny wires are installed, but the BW hasn't needed anything that's not there. Will check the driver-side frame in the morning and see what I have.
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Old 03-13-2012, 06:39 PM   #22 (permalink)
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Day 4 - Post Mortem

Observations:
1. If you don't hook the power wire up for the ignition switch, you can't start it with a key. 30 minutes, trial and error, and deciphering the hieroglyphs in the Scout Manual to solve that issue.

2. Make sure and leave pig tails on the motors you don't plan to replace. I rebuilt as much of the wiring as I could, but left enough to splice.

3. I had to run my own wire for the windshield washer reservoir, which wasn't a big deal. Testing it required hooking it up to the battery, with my youngest pointing the tube at me. It worked and we had a discussion on why I asked him to point it the other way. Also ran new rubber tube for the washer lines.

4. Found electrical tape on sale at $.67 per roll. Burned through five so far.

5. Should have bought more black wire. Got 27 more feet today off the bulk roll. Still good on zip ties, connectors, liquid electrical tape.

Here is what I was able to finish today.

1. Engine wiring, front lights, and steering column finished. Verified truck will start from a key.




2. Started working on the cab wiring. Had to rebuild the wiring to the wiper motor and will need to run new wires to the blower motor. Setup a common ground in the cab to make the grounding process easier. The cab is still a mess, but making progress.

Under column


Fuse Box and initial wire routing


I wrapped the day getting the radio wires squared away and the brake switch hooked up.

Total time: 19 hours over four days. I am guessing I am about halfway done. It's going to need to sit, because I have a fishing trip scheduled with the boys. The Scout will sit until the weekend. My hope is to get some more done Sunday.
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Old 03-23-2012, 08:46 PM   #23 (permalink)
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Day 5 - Post Mortem

1. Got the wipers working, but the washer pump isn't. I am guessing a bad ground. Will look at that later. The Scout manual and the GM switch wiring are different, even though the switch is identical.

2. Larger issue is the light switch that I think is bad, as I can't get the plunger to seat and the lights won't come on. Will pick up a new one tomorrow and keep trying.

Total time spent 21 hours over five days.
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Old 03-23-2012, 09:30 PM   #24 (permalink)
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On the light switch sometimes you have to hold you mouth just right and mess with the button to get the plunger to seat even on a new switch.
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Old 03-24-2012, 08:40 AM   #25 (permalink)
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On the light switch sometimes you have to hold you mouth just right and mess with the button to get the plunger to seat even on a new switch.
X2 after doing hundreds of the lights switches they still have me pissed before I get them together, other times they slide right in Also remember the dome light circuit is ground controlled.
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