6.9 truck harness to 7.3 IDI engine harness

[bzdulab]

I have a 1986 F350 that I put a 7.3 IDI in. The truck was originally a 460 gas job but I decided to do the diesel swap. I found an 86 F-250 6.9 that was junk and I was able to get it for the wiring harness. I pulled the wiring harness out of the 250 and put it in my F350 in place of the gas engine wiring harness. The engine I'm using is a 93 7.3 IDI from a truck with an automatic transmission. It will now have a four-speed transmission.

What I am trying to do is connect the two wiring harnesses from the engine to the truck harness. Wiring is not my strong suit so to say. I have a couple of different manuals for the 1986 truck and I went online and found a couple of different wiring diagrams for the engine harness.

I know I am not going to need the throttle position sensor and I read it's only one wire for power to the injection pump. I'm not sure what other wires go where in terms of sensors the glow plug warmer and idiot gauges.

I know there have been plenty of these swaps but I'm having trouble locating diagrams and tips on how to do the wiring. I had a post over on Ford truck enthusiast but not much help there so I figured you guys over here might be of help with this wiring. Any help would be greatly appreciated at this point because I'm at a standstill in my build project now until I get the wiring done.

Thank Bob

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[bzdulab]

I should add that the 86 wiring harness does have AC wiring as well in it that I am not going to be using.

 

[IDIoit]

i would stop right there, gut it all and use a aftermarket wiring harness.

i have done several trucks with the EZ wire 22 circuit wiring harness.

they cost $200 and i usually have another $100 into pig tails, solder, shrink wrap, etc.

i also splurge on good gauges.

heres my daily driver and my sons 61 that is near complete, that ive rewired with new gauges.

 

[IDIBRONCO]

i would stop right there, gut it all and use a aftermarket wiring harness.

i have done several trucks with the EZ wire 22 circuit wiring harness.

they cost $200 and i usually have another $100 into pig tails, solder, shrink wrap, etc.

i also splurge on good gauges.

This would probably be the easiest thing to do right now. It would certainly give you the least amount of chances for having electrical issues later. As for the glow plugs, you can buy what is basically a stand alone glow plug wiring harness.

 

[bzdulab]

That looks good. I did consider the universal wiring harness because the directional plug in my fuse panel is melted. I was going to try to replace it with the fuse panel from the gas engine wiring harness but would rather not get into that type of a project. The previous owner of that parts truck that had came out of with the 6.9 had rigged it up so that the directional fuse was just hanging and the directional circuit was not being used on the panel.

I would like to keep the factory dash panel with the gauges if I could because the aftermarket gauges are not in my budget. But if it comes to it I could go aftermarket gauge route.

Well I guess I will go the universal wiring harness route since it's being recommended.

 

[bzdulab]

Well I decided to go with your suggestions and I ordered this...

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[IDIoit]

i also grab some relays and pigtails and run relays for:
headlights
fuel pump
and any other aftermarket stuff like lights etc.

 

[IDIoit]

this book is instrumental when rewiring.
you could rig this up to your stock gauges.
but would be smart to get a set of aftermarkets.

1986 Ford Bronco F150-F350 Truck Electrical Vacuum Troubleshooting Manual Book | eBay

Bronco F150-F350. Electrical & Vacuum. Physical Paper Manual.

www.ebay.com

 

[bzdulab]

I just put the order through for the book. I did get this manual a few weeks ago as well.

Would I be able to use the factory plugs if I cut them as pigtails? And I will use the relays for lights horn etc.

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[IDIoit]

you most certainly can, remember...
SOLDER AND SHRINKWRAP!

 

[bzdulab]

I was going to use the crimp connectors with the heat shrink jacket. I got a whole bunch of those connectors and not a soldering iron.

 

[bzdulab]

This would probably be the easiest thing to do right now. It would certainly give you the least amount of chances for having electrical issues later. As for the glow plugs, you can buy what is basically a stand alone glow plug wiring harness.

Would the harness you're referring to be the harness for the powerjoke on eBay?

 

[bzdulab]

It's been so long since I've put this old harness in my truck that I forgot that there was a melted section of the harness as well as the fuse panel. It's definitely a good idea to go with the EZ wire harness after seeing this. I believe the melted wire went to the AC system. Would it be possible to use the old plugs if I cut them as pigtails? I will get some new pigtails but I'd like to reuse some of the old ones as well. I'm getting close to the end of my budget for now.

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[IDIBRONCO]

Would the harness you're referring to be the harness for the powerjoke on eBay?

I was thinking along the lines of what's sold by Classic Diesel designs. They have a glow plug relay relocation kit.

 

[bzdulab]

I was thinking along the lines of what's sold by Classic Diesel designs. They have a glow plug relay relocation kit.

I didn't know about them. I will be looking into that.