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96 Explorer harness re-work - What's left in original?

bsquared

Contributor
Sr. Member
Joined
Dec 4, 2010
Messages
960
I finally dug into "Old Crusty", the original harness that took it on the chin in the fire. Lucky for me that I had not tossed the rats nest of left over wires from the 96 Explorer harness rework. I had plenty of same color wires to splice in.

I think I was lucky in that the firewall connectors were spared and I was able to splice all of the bad spots pretty easily.

Couple of big questions....The 96 Explorer harness did not have a wire for the 3G alternator I'm running, right? (98 and later did, or that's what I took from the video) So I'll keep the 10 gauge wiring I've been running in my original harness.

Only other thing that stands out is for the starter relay. Wire 262 (brown) used to tie in to 16 (red/grn) as it went into the firewall and over to the coil. 16 got fried and coil is now gone, replaced by coil packs. So I can just tie 262 into 16 at the firewall connector, right?

Hopefully make some headway on the block / intakes tonight.

Here's some pics of where I was and am now. Thanks in advance! B2
 

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904Bronco

Contributor
Bronco Guru
Joined
Sep 28, 2004
Messages
5,749
Loc.
San Martin, CA
My 96 motor and harness has the charging feed wires... Large black wire with an orange stripe. Early ones had two fuseable links at the supply end, later Explorers have a large fuse in the distribution block. (I think...) That 10g wire will not last long with an Alt that is usually configured at 130 amps.
Most aftermarket kits run a 4g wire with a 150amp mega fuse.

The Brown wire is not needed with Explorer... I am not up enough on factory harnesses to give direction on your question. If memory serves me, that wire provided a full 12v when the starter relay was closed, to the coil to aide in start up.
 
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