Wiring problem

TurbineJon · Jan 28, 2017

Hi
I was working on my 1999 Defender Td5 trying to repair a faulty brake light. I have found that all of the original wiring insulation has gone very hard and the copper wire has turned black and cannot be soldered.
If the solution is to replace the wiring with new, does anyone have details of wire lengths so that I can make my own loom? Alternatively does anyone know where I can get a rear section harness?

zeaphod · Jan 28, 2017

If it's just one or two wires, you can still solder them by cleaning the black corrosion off with sandpaper.

TurbineJon · Jan 28, 2017

zeaphod said:
If it's just one or two wires, you can still solder them by cleaning the black corrosion off with sandpaper.

Hi
Its all wires and all insulation is cracking and has gone very hard.

Foxyred · Jan 28, 2017

Autosparks

zeaphod · Jan 28, 2017

TurbineJon said:
Hi
Its all wires and all insulation is cracking and has gone very hard.

Then as above, it's a new loom unless you have the time to make one.

stewd · Jan 28, 2017

Black copper is a sign of salt corrosion most possibly caused from the salt and dark flicking up from the road.

Go to vehicle wiring products website and order some new rolls as they supply any colour or wiring so you can match the pattern as it should be. (Cheaper to make your own loom than buy pre made)

TurbineJon · Jan 28, 2017

stewd said:
Black copper is a sign of salt corrosion most possibly caused from the salt and dark flicking up from the road.

Go to vehicle wiring products website and order some new rolls as they supply any colour or wiring so you can match the pattern as it should be. (Cheaper to make your own loom than buy pre made)

Ok
Many thanks
I will make my own loom,
Does anyone have a set of length measurements so I cn make one on the bench rather than on my back in the mud
Jon

stewd · Jan 28, 2017

No Idea on the length but I normally get a couple bits of string, to work out a length (laying in the mud) then go inside and make it in the warmth.

Barbados · Jan 28, 2017

The dreaded black wire corrosion. You will have a tough time soldering onto the corroded wires, even with flux and well cleaned. You will have to flatten the wire so that you get all the strands clean if not you wont have a proper connection.

While at it, look for loose insulators as I have discovered on mine as in pics below. You will see them bare because the blue insulation came off. I soldered them, insulated and wrapped them so the insulation wont come off. i could have used shrink wrap but that would have needed the wires to be cut.

.

flat · Jan 28, 2017

I had a few areas like this. I cut back the wires by a few inches till it was 'good' and soldered in replacement sections

Wiring problem

TurbineJon

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zeaphod

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TurbineJon

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Foxyred

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zeaphod

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stewd

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TurbineJon

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stewd

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Barbados

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flat

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