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Question:

Why is wiring harness burning up?

I have a 1994 toyota pickup 2wd. Just recently it had a wire burn up on the wiring harness running to the alternator from the main harness. It burned the ground clean off the alternator the first time then I fixed the wiring and the second time it did it again but on the ground running to the fender but it was the same wire but on the other side of the plug in. When going down the road, the lights and radio would start skipping then the truck motor would start skipping also then just shut completely off. Thats where i found that wire burnt up. I can't fix it after two attempts. Please help

Answer:

OUCH! you may have a wire somewhere with the installation cracked or coming off touching ground. If a cluster of wires in a cable burn up, it could be costly replacing the whole thing, hope that's not the case?
When a vehicle gets to around 15 to 20 years old is when wiring problems usually develop. The places that I would at look first are all the ground wires, ground to engine, engine to chassis, chassis to body, etc. As the ground wires on a vehicle get crusty with age you get bad connections (it's called resistance in the circuit), this will cause back feeds.and cause components to go haywire. This is what I would do, clean off the surface where the wire goes, make it shine and put a dab of never seize on it. Your ground connection at that point will last for many years. You will want to check the ground wires themselves, when they get old enough they can fall apart inside under the insulation. While your at it, also go over the positive side of the circuit like the battery cable to the starter solenoid where you have the positive feed connection for inside the cab. One more thing, pull the harness plug that goes into the firewall to see if your contact points are crusty and corroded. This is the best I can give you without looking at it, I think it will help you.

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