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Careful with aftermarket headlight wiring harness

Discussion in 'General Tundra Discussion' started by SoCalTundy, Aug 25, 2020.

  1. Aug 25, 2020 at 2:48 PM
    #1
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    My AC stopped working over the weekend. Took it to the dealer today and they found out the wiring harness to my trd pro headlights was rubbing against a line from the AC condenser and ripped it. Caused a leak in the coolant. $700 to fix. Just a heads up for those who have installed or are installing the newer tundra headlights with harness. Make sure it’s not rubbing against any other hoses. 756864D7-60DF-4E6A-BBB1-0114A2F233AD.jpg
     
    Last edited: Aug 25, 2020
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  2. Aug 25, 2020 at 3:12 PM
    #2
    TundraPHX

    TundraPHX Ryan started the fire.

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    I installed mine just like this.

    upload_2020-8-25_15-12-24.jpg

    Are you saying that the harness rubbed right through that metal pipe?
     
  3. Aug 25, 2020 at 3:25 PM
    #3
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    The truck is still at the dealer. I have not seen it in person, but it does appear to be a metal or aluminum pipe. The picture is from the dealer sent to me. They said “there’s some sort of harness to your headlights or fog lights rubbing against the pipe that caused the issue.” The only one I’ve installed is the headlights one. The picture clearly shows a break where both meet. Could the harness be generating heat on a pipe that delivers contents that are cold?
     
  4. Aug 25, 2020 at 3:28 PM
    #4
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    I followed those instructions too and added the zip tie there. The dealer told me there’s a smaller leak where a zip tie is located. He didn’t show me that one, but that’s probably the zip tie he’s talking about.
     
  5. Aug 25, 2020 at 3:33 PM
    #5
    Tundra234

    Tundra234 New Member

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    I'm wondering if it arced through? I wouldn't think that harness gets that hot. How long was it installed?
     
  6. Aug 25, 2020 at 3:36 PM
    #6
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    Headlights were installed last October. It could also be a combination of the hot weather and harness on the pipe.
     
  7. Aug 25, 2020 at 3:45 PM
    #7
    AZTundra

    AZTundra No Longer a New Member

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    Wow, going to have to check mine this weekend. I installed the ihacker harness with oem headlights in December.

    @iHacker ever hear of any issues like this before?
     
  8. Aug 25, 2020 at 4:01 PM
    #8
    fisherman951

    fisherman951 LT dreams ....

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    Gotta keep my eye here just in case
     
  9. Aug 25, 2020 at 4:03 PM
    #9
    Yzed608

    Yzed608 New Member

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    Following, I'd have to check to make sure but I'm pretty sure I did the same thing.
     
  10. Aug 25, 2020 at 5:36 PM
    #10
    JohnLakeman

    JohnLakeman Burning Internet Daylight

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    I just checked mine. That's the small aluminum refrigerant pipe (from condenser to cabin?) where it passes through the radiator bulkhead.

    Apparently, old training must have turned on an alarm for me; I covered the braided insulation with ribbed flex conduit, and then used a zip tie to cinch the harness to the pipe very tightly at that location. Relative movement between wires or hoses will eventually eat a hole through. It's strictly from friction of the insulation on the pipe, and that braided insulation is probably woven of tough aramid fibers. The best solution would probably have been to drill another 3/4" hole in the plastic bulkhead trim, but that trim is made to be removable without disturbing the AC connections.
     
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  11. Aug 25, 2020 at 5:40 PM
    #11
    TundraPHX

    TundraPHX Ryan started the fire.

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    Soooo, off to Amazon to buy some ribbed conduit. Great info. Thanks for sharing.
     
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  12. Aug 25, 2020 at 5:50 PM
    #12
    JohnLakeman

    JohnLakeman Burning Internet Daylight

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    You can get flex conduit in polypropylene, polyethylene, or even nylon (aramid). PP and PE will be softer, nylon could be as destructive as the braided unless all relative movement between pipe and harness is stopped.

    I've prevented the two from rubbing, but I'm still thinking about, and dreading, the best solution. Making a new hole for the harness will mean having to either unwire the harness under the dash and pull it back through, OR, cut and splice under the hood. I hate splices. :mad:
     
  13. Aug 25, 2020 at 6:07 PM
    #13
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    BD446173-B775-42AB-A680-DA2767B0D45A.jpg B236A3B3-0403-419E-B1E2-CBD0B41251E2.jpg
    I’m back from the dealer. Here are pictures of the damage $629 later after 20% off service coupon. Notice the two brown spots. The larger one has a hole in the aluminum. The smaller brown spot is where the zip tie was. Now I have to run through and examine all the harness wiring to make sure it’s not damaging anything else especially when it runs through the conduit into the cabin. That would be a MAJOR problem if it’s eating into all of those wires.FDBB1294-4FDD-4E12-85A8-3CF237D2FA2D.jpg
     
  14. Aug 25, 2020 at 6:10 PM
    #14
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    I’m not knocking @iHacker by any means. The harness does what it’s supposed to. It may be a good idea to re-evaluate install instructions though.
     
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  15. Aug 25, 2020 at 6:30 PM
    #15
    JohnLakeman

    JohnLakeman Burning Internet Daylight

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    Wow. That looks like a chemical erosion rather than abrasion. Shut my mouth. :eek:

    The darkened areas also look like the braided insulation has been heated. That pipe won't be cold like you were thinking because the cooling doesn't occur until the refrigerant is expanded to gas in the cabin AC. The compressor raises the refrigerant gas pressure, the condenser takes out the heat absorbed from the cabin, and then the refrigerant is condensed to a liquid state in the process.
     
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  16. Aug 25, 2020 at 6:37 PM
    #16
    JohnLakeman

    JohnLakeman Burning Internet Daylight

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    Have you had any battery problems or had to replace the battery lately? I'm wondering if you've had battery acid leak out and down the harness, trapping acid at the points of contact between harness and refrigerant pipe?
     
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  17. Aug 25, 2020 at 6:53 PM
    #17
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    No the battery is clean. That aluminum pipe is really thin and the braided wiring is really abrasive now that I examined it. I can see how this would have happened.
     
  18. Aug 25, 2020 at 6:55 PM
    #18
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    DAF39B83-85C2-4B58-AFD9-4A8D5CD1090F.jpg This is what I did to move it. Lost a pin to the black plastic cover in favor of the zip tie but no big deal64795E5B-20D0-430B-90B2-558D531EB43E.jpg
     
  19. Aug 25, 2020 at 8:11 PM
    #19
    BAZZMAZZA

    BAZZMAZZA New Member

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    Checking mine tomorrow I have the Ihacker Harness and installed it per his directions. Thanks for posting this up. This should be posted in the lighting section for a broader distro. Lots of folks have used that harness to install upgraded headlights.
     
  20. Aug 25, 2020 at 8:18 PM
    #20
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    I think it’s just a good idea not to let the harness wire sit on the aluminum pipe. It’s possible a wet harness over time could have caused corrosion on the pipe too along with rubbing.

    In addition, I looked at how I ran the harness through the firewall into the cabin and if you follow the instructions and used the rubber conduit to run the wire you should be fine. No issues there. 96372590-CB4B-4C3F-B62E-5BD24EC55684.jpg
     
    Last edited: Aug 25, 2020
  21. Aug 25, 2020 at 8:26 PM
    #21
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    The damage was on the aluminum pipe that runs from the condenser on the grill side. That last picture was to address another concern that really isn’t one if you follow the install instructions. I thought the harness cable was going to be rubbing against all the other wires going through the firewall, but it’s not. It’s running through its own conduit.
     
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  22. Aug 25, 2020 at 8:29 PM
    #22
    TundraPHX

    TundraPHX Ryan started the fire.

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    I deleted my comment because I thought I was being obtuse and had to re check. Ok good I was correct, and am going to put some conduit on it tomorrow evening just to be sure.
     
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  23. Aug 25, 2020 at 10:14 PM
    #23
    1lowlife

    1lowlife Toxic prick..

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    Thanks for posting.
    Thinking about upgrading the headlights on my 2014 before the end of the year.

    I'll drill holes for my zipties before I attach anything to the AC pipes..
     
  24. Aug 26, 2020 at 6:21 AM
    #24
    iHacker

    iHacker Well-Known Member

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    Ohh man :eek2:


    I’m sorry to hear about the problem with your AC condenser lines, I just saw your thread and checked mine with a flash light and everything looks clean no corrosion or any signs of damage to the lines but just in case I’m going to relocate this zip ties in the next days, my installation has been there since September 2017 and luckily nothing like this happened to me.


    Not sure but probably the weather or other external factor caused this not sure if condensation buildup in the pipe kept moisture in the braided sleeve for prolonged periods of time or if something leaked causing this corrosion or at least that is what comes to my mind.


    I’ll share your thread to all my thread followers to inspect closely this spot to avoid any future problems, so sad you had the unfortunate part of this :(


    02B5B5A3-64D4-4D33-9E94-099CCA228DBB.jpg

    B477C3C4-DB15-4C51-B648-9DAE098BFE8D.jpg

    753D4CD2-4F4E-40AA-A560-ACBF74F4A766.jpg
     
    Last edited: Aug 26, 2020
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  25. Aug 26, 2020 at 6:24 AM
    #25
    iHacker

    iHacker Well-Known Member

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    To me seems like something very abrasive leaked over the braided sleeve and combined with condensation in the pipe caused this corrosion and damaged the pipe
     
    Last edited: Aug 26, 2020
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  26. Aug 26, 2020 at 7:25 AM
    #26
    SoCalTundy

    SoCalTundy [OP] Not a new member

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    Icon Stage 2. Total Chaos UCA. Flowmaster super 50. 20’ black rhino pismos. 35x11.50r20
    Yup I totally agree. The only thing I can think of is the hard water when I wash the truck. I really spray in the grill to get all the bugs. It probably soaked the wire and sat on top of the AC pipe.
     
  27. Aug 26, 2020 at 7:58 AM
    #27
    iHacker

    iHacker Well-Known Member

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    I was thinking about the same thing, hard water and we aren’t 100% certainly sure about the chemicals used in car washes and detailing products, that must be something very abrasive.


    Aluminum is very good maintaining rust away
     
  28. Aug 26, 2020 at 1:00 PM
    #28
    Jeffro22

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    just checked mine and I guess I came out better for once by not following instructions.

    I ran my wire harness differently

    thanks for posting and sorry to hear about this
     
  29. Aug 26, 2020 at 1:41 PM
    #29
    gdiep

    gdiep I like cookies

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    I just checked mine. I don’t see any signs of corrosion and I’m up in the Northeast where we use a lot of salt on the roads. Very curious. Sorry for your bad luck.
     
  30. Aug 27, 2020 at 6:57 AM
    #30
    manhster

    manhster New Member

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    I installed mine in April and removed the ziptie to the line. I saw a start of something. Is that coincidence? Or actual friction erosion? Anyway, I relocated it.
     
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