Author Topic: 89 Dodge W250 Electrical problems  (Read 2105 times)

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Offline Kidd

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89 Dodge W250 Electrical problems
« on: June 13, 2010, 08:59:54 PM »
I'm new to the site and I have some real bad electrical problems. I just got a good bit of money for my gradutating and I would like to completely rewire it so the electrical is 100 percent fixed, I am planning on doing a Cummins diesel/5 or 6 speed manual swap in it , right now it is a 318 or 360 Im not sure. Can anyone give me some tips/pointers to redo the electrical and upgrade it  a lil also because Ive been told by a bunch of people that the only real problems with dodge is their wiring  can anybody help me with this?

Offline Dork

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Re: 89 Dodge W250 Electrical problems
« Reply #1 on: June 13, 2010, 09:24:46 PM »
welcome

In my opinion, the wiring isn't as bad as many make it out to be (unless it's been butchered by previous owners), especially in that era. 
Before tearing wiring out, I'd spend some time with it and see what you can fix.  Bad grounds are the cause of a lot of problems.  May also simply have some loose connections. 

A total re-wire is going to be a lot of work.  There are no plug & play kits available like you may have seen for Jeeps and popular muscle cars.

Pick an issue and post it up, then another.  You'll learn a lot here, and that experience will help you troubleshoot other problems.  And even if you so re-wire it later, the expereince you gain trying to fix this system will pay off.
'85 3/4 Ton Dodge , Utiline longbed , 318 , 4-speed

Offline Kidd

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Re: 89 Dodge W250 Electrical problems
« Reply #2 on: June 13, 2010, 10:36:57 PM »
Well the first thing i would like to do is get the alternator to start putting a charge into the battery, the alternator is brand new and i know the battery is good. any ideas as to what the problem is? ???

Offline s ǝoɾ

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Re: 89 Dodge W250 Electrical problems
« Reply #3 on: June 13, 2010, 11:03:17 PM »
Please read the topic "where my electricity went" before asking further questions.

THEN read "confirmed fixes"

All that just to tell you to inspect the green wire on your alternator, and the other one regardless of red or blue color.

But you must read the links, the damage often hides inside.

Continuity/test light testing is absolutely not sufficient.

We need solid digital multimeter readings and the location where BOTH probes were placed to get those readings.

Avoid replacing any part that you have not proven to be faulty through extensive testing.

Offline Kidd

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Re: 89 Dodge W250 Electrical problems
« Reply #4 on: June 14, 2010, 01:19:44 AM »
ok i read those topics and now i am at a crossroad. do i try to find all the colors to keep it all original or do i just go and get a few diff colors of wire with like two guage sizes to every color? and BTW my wiring harness is hacked to all kinds of hell , theres a toggle switch to start the thing  , none of my guages work and when u turn on the lights the damn plow lights  and windshield wipers come on. this is gonna be a nightmare!!!! >:(

Offline s ǝoɾ

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Re: 89 Dodge W250 Electrical problems
« Reply #5 on: June 14, 2010, 02:51:36 AM »
I used to work on both big trucks and generators. Man what a joke. Open the panel of a generator to find a bundle of wires as thick as a beer can, ALL WHITE!  >:( With them being all the same color, it makes it a royal PITA to trace unless they have legible wire tags running all along them. Then open up some of the big truck dashes and same thing but ALL BLACK.

If you only use 2 or 4 colors, you will be in for a world of hurt.
If you use generic wire in 10ft roll from autozone you may also be in big trouble. The wire is cheaply made and has a cheap non high heat resistant insulation. Not being as oil/fuel resistant either.

You want high grade automotive wire such as TXL or marine grade tinned wire. Not old scrap you salvaged from a '76 ford.

There are atleast 20 places that the factory wiring needs improved on. Every single switching mechanism in there has a design flaw
  • blower switch
  • ignition switch
  • headlight switch

None of the gauges are anywhere close to accurate, all are merely suggestions. Speedo is the most accurate and it's crap. The fuel gauge is more of a "yes or no", temp gauge is crap, oil psi is crap, amp gauge is crap (I think volt gauges didnt come out til a year or 2 later)

Headlights are quite a bit dimmer than they should be due to high voltage drop across the wires/switch.

Luckily a cummins truck doesn't need many wires to run and operate. Then you can work on cabin creature comforts one at a time, along with lighting system and you are done.

I would tell you to get a wiring diagram, but then again, I'm not sure how good that will do you, since between the engine swap/correcting factory deficiencies/gauge/lighting upgrades, the end schematic would be completely different from any factory service manual.

Best to try to break each thing down one at a time.
Avoid replacing any part that you have not proven to be faulty through extensive testing.

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Re: 89 Dodge W250 Electrical problems
« Reply #6 on: June 14, 2010, 06:18:14 AM »
your best bet would be to get a FSM [factory service manual]  and with it you could rewire the whole thing real easy / plus if your gonna do the Diesel swap later get both manuals / below is the link to the classifides on here and the manual you need

1989 dodge FSM and diesel supplement
put your truck info HERE
MOPAR TO YA! AARON HOWORD TOWNSEND / SLANTEDMIND---GOD BLESSDODGEBOYS FSM STORE
ramchargercentral@hotmail.com
DO NOT use the site IM,s to contact me  l have them turned OFF

Offline Kidd

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Re: 89 Dodge W250 Electrical problems
« Reply #7 on: June 14, 2010, 02:00:45 PM »
so should i worry about doing the cummins swap then do the electrical? im not planning on running the current engine/tranny combo on the road because the truck was a plow truck and my pops beat the eyes out of it, and does anybody got or know of a good place i could find a dodge w/a cummins and manual tranny for sale ? i want it to look like it was a factory diesel so if it was a complete truck it would be the best . as for wire i wasnt gonna use autozone, i was gonna use a&a  auto wire lol,
im gonna go with the txl wire , anyone know a good site to buy like a kit  of wire or could you give me an estimate of how much wire i would need, im prolly gonna get 2 or 3 sizes  12,14,16 i found this website that sells txl wire in 100 foot lengths for 20 bucks does that sound right? they also have twelve colors, i think 50 foot should suffice though ? yeah i know i ask a lott of questions, electrical is not somthing i really like messing with but if i want to keep the truck i gotta have it roadworthy by the first week of august to take on vacation or my dads gonna send it to the crusher

 

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