Forum Discussion

IBcarguy's avatar
IBcarguy
Explorer
Nov 03, 2013

Damaged trailer wiring harness

Today when parking the TT in a tight spot, I had to jack knife the trailer to get it in and the large trailer wiring harness got caught in the hitch and smashed/cut the wiring harness about 2' from the large plug that connects to my truck. Tore it up pretty good and luckily it seems that it only blew a 20 amp fuse in the truck. I can cut away the damaged insulation and wires, use crimp connectors and tape it up or even solder the wires but I know it will create a huge lump in the harness that will bother me forever. Is there a preferred way of repairing this that leaves a clean, neat appearance?

18 Replies

  • PLEASE solder & shrink tube conenctions. I HATE those crappy crimp on connectors! Works great for about a month but then the connection starts to corrode & then you start having problems. I had to replace a bunch of crimp connectors on the backside of my coach. Apparently, prior owner needed to add a connector for the toad.
    Once cleaned out all problms\issues with tail lights gone.
  • Buy and install a new plug if you have enough length left over. MY catalog shows around $9 for a plastic plug and $43 for a 8 ft cord
  • 69 Avion wrote:
    IBcarguy wrote:
    Thanks guys, your suggestion to replace it makes sense. I just crawled under there and the cable is only about 7' long and goes into a long box bolted to underside of the frame. Looks like a an easy job to just replace it.

    Buy the right length of 7 conductor wire and make sure you get the heavy duty wire with the #10 black and white and the #12 Blue for the brakes. Everything else should be #14. Also, make sure you put the new plug on the correct end. If you do it backwards you are going to have a heck of a time getting the wires to line up in the plug.


    Why go through all of that. Since he has to replace the cable anyway, buy the 7 wire cable with the TV plug already attached and molded to the end. Use the other end as a color guide to attach the new cable and forget it.
  • IBcarguy wrote:
    Thanks guys, your suggestion to replace it makes sense. I just crawled under there and the cable is only about 7' long and goes into a long box bolted to underside of the frame. Looks like a an easy job to just replace it.

    Buy the right length of 7 conductor wire and make sure you get the heavy duty wire with the #10 black and white and the #12 Blue for the brakes. Everything else should be #14. Also, make sure you put the new plug on the correct end. If you do it backwards you are going to have a heck of a time getting the wires to line up in the plug.
  • RoyB's avatar
    RoyB
    Explorer II
    I would definitely replace the damaged trailer cable with a new one. Go to ETRAILER.com to purchase what you need. Etrailer has two lengths for this item so be sure of the length you need.

    It will be an exact replacement item including the correct color of the seven leads used. Replacement will an easy task in the junction box you have found and will be color for color when replacing the leads.

    ADDED NOTE:The replacement cable will look something like this:


    Etrailer also has self help videos for these type of replacement items.

    I helped a guy patch his cable up that he got damaged at a camp site since I had some crimp connectors, tape, and heat shrink on hand. It was a good fix doing this for him to make a trip back home and get a new one ordered but it just makes good sense to me to replace a damaged cable with a new one. You get a new molded 7-way connector that will have fresh contacts as well.

    Roy Ken
  • Thanks guys, your suggestion to replace it makes sense. I just crawled under there and the cable is only about 7' long and goes into a long box bolted to underside of the frame. Looks like a an easy job to just replace it.
  • Buy a new harness with plug on it and wire it to the box under the trailer hitch where the current one connects.
  • Solder and heat shrink. Either way you will see it.

    Could always replace the whole thing.