Upfitter Wiring Harness Discussion

I used a wide nylon strap to slide under battery to lift the battery out but for a separate mod.
 
V8Notch said:
Hi All. I'm planning to install the harness this week.

How did you manage crimping the different wire gauges? Most of the ford wires are much smaller gauge. Just crimp it tight and give it a tug to make sure it's gripping?

Did you run the wires down and under the evaporator lines?

View attachment 239193

On a '24 can you actually fully remove the upfitter box to do this on a bench?

Thanks!
Click to expand...
To answer the gauge question, if the gauge is too small for the crimp size, you will get a poor connection no matter how hard you try to crimp it. I use a double-over method. Strip twice as much as needed for the crimp and double it over as tight as possible. Be sure all of the wires enter the crimp connector and make sure you do not get any insulation in the connection.
 
V8Notch said:
Hi All. I'm planning to install the harness this week.

How did you manage crimping the different wire gauges? Most of the ford wires are much smaller gauge. Just crimp it tight and give it a tug to make sure it's gripping?

Did you run the wires down and under the evaporator lines?

View attachment 239193

On a '24 can you actually fully remove the upfitter box to do this on a bench?

Thanks!
Click to expand...
Forgot to mention that there are step down butt splice connectors. Crimp and Solder Seal varieties. Just know that the fuse size cannot be increased just because you add larger wire to the upfitter pigtail.

Step-Down Heat Shrink, Crimp & Solder Seal Butt Connectors

Step-Down Heat Shrink, Crimp & Solder Seal Butt Connectors
www.jttproducts.com www.jttproducts.com
 
Canyon Trekker said:
To answer the gauge question, if the gauge is too small for the crimp size, you will get a poor connection no matter how hard you try to crimp it. I use a double-over method. Strip twice as much as needed for the crimp and double it over as tight as possible. Be sure all of the wires enter the crimp connector and make sure you do not get any insulation in the connection.
Click to expand...
I should have been more clear. I'm using the CB Lighting harness which has larger wire gauge and the crimp butt connectors. I thought of that (doubling-over) but I'm not a big fan of the idea. This is what I've used in the past. Both wires go into it and it's a single crimp. I might cut these butt style crimps off and use these instead.


trmrzla said:
Yes you can pull the whole box out. One connector, usually under the battery tray, the positive lead and then the two clips on the back of the box and the whole thing will pull out. Makes it much easier regardless of what solution you go with.
Click to expand...
Yes, I got that figure out. You can see the connector in this picture. It's under the buss bar.
IMG_0868.webp

IMG_0869.webp
 
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V8Notch said:
I thought of that but I'm not a big fan of the idea. This is what I've used in the past. Both wires go into it and it's a single crimp. I might cut these butt style crimps off and use these instead.



Yes, I got that figure out. You can see the connector in this picture. It's under the buss bar. View attachment 239225
Click to expand...
"I thought of that but I'm not a big fan of the idea. This is what I've used in the past. Both wires go into it and it's a single crimp. I might cut these butt style crimps off and use these instead."

https://www.prowireusa.com/19205-0003

That works. Just need to make sure both wires fit without losing or fraying any strands and add shrink wrap.

This would not be good to use as a ferrule, just in case anyone would consider doing that. A ferrule connection requires a special crimper that does not elongate the sleeve.
 
V8Notch said:
I thought of that but I'm not a big fan of the idea. This is what I've used in the past. Both wires go into it and it's a single crimp. I might cut these butt style crimps off and use these instead.



Yes, I got that figure out. You can see the connector in this picture. It's under the buss bar. View attachment 239225
Click to expand...
Yep that gets the power to the relay box. The other connector gets the power to the switches. That's the one under the battery tray
8942.webp
 
V8Notch said:
Hi All. I'm planning to install the harness this week.

How did you manage crimping the different wire gauges? Most of the ford wires are much smaller gauge. Just crimp it tight and give it a tug to make sure it's gripping?

Did you run the wires down and under the evaporator lines?

View attachment 239193

On a '24 can you actually fully remove the upfitter box to do this on a bench?

Thanks!
Click to expand...
I ended up just popping tabs on the side of the upfitter fuse box, so that was able to pull it up and move it free. I was then able to get at the wire bundle and make the splices. I just routed it so it sits on my main fuse box.

IMG_9596.webp
 
trmrzla said:
Yep that gets the power to the relay box. The other connector gets the power to the switches. That's the one under the battery tray
View attachment 239229
Click to expand...
I need to do this over the summer. I ran out of time for this project last summer. I have the harness sitting in my garage next to the mirror lights from subtle designs. Both projects I want done!
 
Are the Super Duty upfitter harness kits no longer available?
 
Canyon Trekker said:
Use the OTC version listed above by @Godzilla/Tremornator It's a much better design than the one in the link you posted.
Click to expand...
I concur. For one, you should ground the accessory to the closest frame ground. No need to return it all the way to under the hood.
 
The Evil Twin said:
I concur. For one, you should ground the accessory to the closest frame ground. No need to return it all the way to under the hood.
Click to expand...
Exactly! That's why we offer our solution without grounding, but there's always our separate ground solution if a customer wants.
 
trmrzla said:
Exactly! That's why we offer our solution without grounding, but there's always our separate ground solution if a customer wants.
Click to expand...
What about me, with no upfitters yet? How shall I proceed?
 
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