ZJ door wiring harness fix write up - JeepForum.com
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Unread 02-23-2008, 12:36 PM   #1
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1994 ZJ 
Join Date: Apr 2004
Location: chilton-haynes<$20
Posts: 2,450
ZJ door wiring harness fix write up

REAR WINDOWS NOT WORKING.This is from my first repair.. The butt connector obviliously not the correct solution. I had previously cut the rubber boot off long ways... CUT THE BOOT FROM THE BOTTOM SIDE. Save the rubber boot. The boot is clipped to the door, but I can't remember how I removed it .It may just have 4 tabs that need lifted up. The boot is just press fit at the body , Pulls out rather easily

Next step was to test the function of the windows with a jumper wire.. They worked fine..

I stripped the wire about 1/4" . Tinned the ends with solder . Cut about a 6" jumper wire and coiled into a loop, Tinned the ends with solder. Then place 2 pieces of heat shrink on the jumper wire. Clamp together with alligator clips the apply heat and solder to the joints, remove clips. keep the joints as small as posssible to allow for more flexability..slide heat shrink over solder joints, shrink with solder iron. Sorry I forgot to take pics of this step.

Here is a kink I added about soldering

Next apply some liquid tape to the other broken wires. It's messy but it may stop it from shorting. I did notice that I missed a couple of spots. I will fix them later.

Next use a couple of small nylon wire ties to bundle it together. Just snug but not tight, you want the wires to move. Clip excess tie ends off.

Next put the rubber boot back on,,, make sure you get back into the opening at the body to protect the wires from rubbing on the metal. I then put a couple of nylon wire ties around the boot. Clip the ends of the ties. I didn't bother with trying to put the boot back in the clip on the door.

94 Grand Cherokee ... 332,000 miles
5.2 liter 242 :)
Rancho 5000 steering stabilizer

Last edited by driabyor; 02-25-2008 at 06:08 AM..
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