Is there any, "sane," method to repair/replace all or segments of cab wiring harness?

[DennisT]

Not the best subject line, however, this general subject must be a nightmare for many of us, if not now, eventually. Example: I have the common issue in my '96 K1500 of the neat little in-door courtesy lamps staying on.....all the time, even with door closed. Even with door plunger switch changed. Yes, I know that lamp is fed by one always hot 12V wire and operation is dependent on when a ground is presented to the other wire. Which means mine have an unwanted, "always on," ground. Bare wire, somewhere, etc. So if repairing that requires replacing the harness from door through the accordion rubber boot at the door hinge, into that hole in the cab frame adjacent to the dash, I have a, .... "nightmare." Because where the wrapped harness enters the cab hole, it immediately goes straight up and, evidently into another huge spiderweb of even more and larger fixed harness. I see few, if any, connecting plugs/sockets in this truck that might lend itself to replacing >sections< of harness. I also realize if a bad wire can be identified, it can be, "cut out," on each end and a single replacement wire run end-to-end for a repair. IF each end can also be identified and accessed ! And that's the rub. In the case of my door courtesy light, the light end is simple to access.......but how to find and access the other end? And so it goes. I think this example is likely only one of many electrical risks/problems that a lot of us end up facing. I've examined several wrecking yard hunks where the dash has been removed, then observed a lot of the hidden harness and it is not something, at my older age especially, I ever want to face. If I'm missing some helpful shortcuts, repair ideas, etc., I'd sure like to hear about them. Thanks for reading, ..................

 

[Frank Enstein]

The ground return wire is white.

You can use an ohm meter to check continuity between the wire in the door and the wire you suspect connects to it.

One with an audible beep is easier to use.

If it isn't keeping ALL the lights on the wire is very likely broken inside the door and grounding there.

They switch the ground so ANY of the switches can turn on the lights.

Use caution when removing/replacing the door panels. Plan to replace the "Christmas Trees" that hold the panel on and don't forget the 7mm head bolts in the armrest and the bigger ones behind it.

Happy hunting!