[Kim]

So I guess that I want to replace the wiring harness as some (maybe most) of the wires a getting a bit brittle and the insulation is cracking (read potential short circuit issues). Anyone ever done this? Are wiring harnesses available and from whom? An the big question - how much?

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[banditsc]

Are you talking about just the main positive and negative cables? I can tell you the alternator to starter positive gets very brittle and the main ground also gets brittle. I'm in the process of replacing those right now with some higher quality stuff. I'm working with someone who does them for 944's, there are a couple of slight changes for the 968 that we are working thru.







I eluded to the brittleness of the positive cable that runs from the alternator to the starter in a previous post back in August I believe about checking that cable. Well almost a year later I got around to replacing it and it wasn't pretty. Part of replacing that cable is pulling it out of the factory harness. Since the alternator exciter wire is also run to the alternator, Porsche bundled these two together in one harness. I just stripped that harness back and found the insulation on the main positive cable was completely shot and crumbled away as I touched it. I also broke half the strands when I tugged on the cable a little. Below is what that cable looks like after I got it out of the car, it's not pretty. You would never know this since it's inside the thin plastic harness sleeve.



   



The main positive cable from the battery to the starter was in much better shape, but the red wire for the starter solenoid that also runs in the harness with that cable had all the insulation breaking away for about 3 feet of the wire.







The main ground I haven't pulled out yet, but I know from cleaning the grounds previously that the insulator is cracking away, I previously taped that up. I have a new cable now, I'm just waiting for a piece of insulator jacket to prevent it from further heat.







The new stuff I'm putting in is 1 and 2 awg welding cable, much beefier then stock. We found the 944 which this kit was designed for, has a slightly shorter positive cable from the battery to the starter then the 968, so I'm waiting on a little longer cable to arrive. The kit also includes a extra supplemental ground, and a extra supplemental positive cable for feeding the fuse box. I'll get everyone more details on it once we work out the 944 to 968 differences. Below is a pic of the kit minus the supplemental ground which isn't pictured. This the Dan Wray Iceshark kit and some of his old stock for those who knew him on Rennlist.



   

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[Kim]

I am looking at that harness as well as the one suppling the fuse block and instrument cluster. Any sources of these wires would be helpful as the dealer cost is probably very expensive. I know that my wires from the battery to the alternator/starter etc are not great as they had to supply some separate wires to the alternator exciter.



Thanks for the detailed response.

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[Mark]

Bandit you can get the battery cables over on rennlist from Robby. Dynamite set.

Kim- I believe the harness is no longer available from Porsche.

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[banditsc]

[quote name='Mark' post='52987' date='May 21 2008, 09:39 PM']Bandit you can get the battery cables over on rennlist from Robby. Dynamite set.

Kim- I believe the harness is no longer available from Porsche.[/quote]



That's actually who I am working with, we are working out the changes to the kit for the 968. Just some minor things.

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[Mark]

No problems with the kit I got, what are you changing?

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[banditsc]

[quote name='Mark' post='53004' date='May 22 2008, 12:44 AM']No problems with the kit I got, what are you changing?[/quote]







He made some changes to the length of one of the cables since it was a little long on the 944, but then it ended up being short on the 968. Also looking at possible supplemental ground locations.

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[prj24149]

I'm going to need the kit too. Any idea on when it will be available and how to buy?

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[banditsc]

Should have details soon, he just sent me a new positive cable yesterday to test and some ExFlex sleeve to put on the main negative. I also need to work out the supplemental ground location and attachment.

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[Mark]

Odd, I don't think RSBarn had any issues putting mine on, I had it sent there since the car was up there when I purchased it.

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[banditsc]

[quote name='Mark' post='53048' date='May 22 2008, 02:18 PM']Odd, I don't think RSBarn had any issues putting mine on, I had it sent there since the car was up there when I purchased it.[/quote]



There was a change to postive cable that shortended it down to 944 sizes, which didn't work well with the 968. He is extending it to the measurement that I got of the original cable plus and inch for good measure.

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[Kim]

If you could make a post when it is available that would be great.



Any ideas on the other harness?

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[PorscheDude]

Try one of the dismantlers.

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[Mark]

Kim- try the dealer if you really think you need a harness, I could be wrong on the NLA part. Probably will not be cheap.



For the battery cables- you can contact robby on Rennlist if you have an account

http://forums.rennlist.com/rennforums/member.php?u=1324



If not let me know and I will PM you his email address.

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[Larry Currie]

I may need the harness that runs from the box on the passenger side of the car. Does anyone have any experience using a cable from a dismantlers? My tech didn't seem too excited about me getting one.

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[banditsc]

A lot of electrical problems can be masked by poor grounds and poor voltage levels. Make sure all those are goods before doing something major.

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[Kim]

So this is a long and hopefully clear question regarding the gauge cluster.



My car (1992 coupe) is a US car and when I bought it I requested a Canadian speedo be installed. This was done from a "donor car" - I had thought that it would be new. Such is life. The numbers on the speedo are a lot bigger (ie their size) than on my original 1992 cab so I am guessing that the speedo part or the whol;e cluster came from a 944S2. It is a 300 kph speedo with no boost gauge so it is not from a 944T and with 300 kph not from a 944 or 944S. But not sure. Maybe it is from a 928 or 911. I know, though, that the guy had a 944S2 donor car on his lot. I am guessing this only because the speedo shows about 8% too high and this is consistent with the number of teeth on the 944S2 speedo vs the 968. I think it is 15 vs 14. This is about 8% difference. More on this.



My voltage gauge and the Oil pressure gauge are toasted. probably happened when the coolant line passing by the alternator leaked and shorted out the voltage regulator. The copper feeds (probably wrong word) are burned. These need to be replaced.



I can buy a US gauge cluster from a 968 to be a donor for the oil pressure and voltage sections. The question is this. If my entire cluster that I have now was from a 944S2, instead of just the speedo part, would the voltage and pressure sections fit in as replacements? Or, can I use the speedo from my car as a replacement for the speedo in the "new" 968 cluster? These parts are extremely expensive new and if I can use the donor cluster from the US 968 I will. I just need to know what is compatible with what.



I am also having made a new harness from the battery, alternator and starter. They were also toast. Also having the A/C converted to R134a from R12.



Looks like the main wiring harness to the fuse block is OK.



More to follow. Anyone want to buy a new car? Or give me a second job? I am a good worker.



Like to get an answer tonight as I need to decide on the donor 968 cluster by noon tomorrow. Otherwise, I will call the Fuhrer himself and have the new gauges shipped from Deutschland.

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