4104 Headlights

TedCalvert · October 15, 2015, 07:11:33 PM

'scuse my ignorance: what's a PENNUJA?
Ted.

4104SoFl · October 16, 2015, 01:46:27 AM

I thought it was the name of the person who sent me the manual.

zubzub · October 16, 2015, 12:48:33 PM

Running new wires to the marker lights is difficult. I would start by taking the lens off marker lights in seeing if the short is that actually in the light socket. When you do have to run new wires I believe the rear wires join up at the rear panel . if you are running the wires you have to take the lens caps off which is difficult anyhow so might as well start there.. Certainly some of the shorting may just be a socket or whatever having shorted out, not all my wires were bad, I just replaced what was bad. FYI the marker light wires were not accessible when the bus was new and are even less so once converted. Best bet is to find one end and pull a new wire with it. If not, discreet holes in cabinets etc may be required.

Gordie Allen · October 17, 2015, 06:48:01 PM

When I first got our 4104, I looked at the front and back panels and almost had a heart attack. There were literally over 100 cotton wrapped wires going to the distribution panel - 90% had no function anymore and all were a fire hazard. I gutted the front panel, preserved the original 3/0 primaries from the start batteries. I installed three 12 post fuse blocks (two hot all the time and one hot when Engine On is switched) wired to the primary, and rewired everything. Also did the same for the rear panel. Tore everything out and replaced with modern electrical components - 4 relays (engine on, reverse solenoid, high idle, and starter) and a 12 post fuse block wired hot from the existing 3/0 primary from the start batteries. Since I had gutted the bus, I a ran raceway down the driver's side to the engine bulkhead and also across to the rear electrical panel.

If you're starting with a fully built-out interior, I'd see if there is a way to install a raceway (4" PVC maybe) even if it's in short pieces from front to back in the back of cabinets, etc.

You can get to the upper and lower markers only from the outside. Remove the lights and drill through the wall/ceiling. Pull the wires through and run to the front panel. Be creative and you can hide the new wires without it looking cobbled. Use #12 DC stranded wire and you shouldn't have to worry about overloading. Do this one circuit at a time. You can have an all new system that is safe and one that you understand completely. Label all wires, fuses, circuit breakers and relays as you go.

jackhanow · October 17, 2015, 09:40:57 PM

before you rewire make sure some one didnt put a single pole bulb in a double pole socket. side lights ussually.

4104SoFl · October 18, 2015, 03:47:22 AM

ZubZub: Took r/r lens and then the entire light off. Wires are bad. Still tring to figure out what I'm going to do.

Gordie Allen: Thanks for the good, smart advise.

Jachhanoe: It is the wiring for sure.

jackhanow · October 18, 2015, 07:38:04 AM

i would get some liquid tape and colored electrical tape and carefully reinsulate the wires most likely the wires are good where they havent been disturbed. the liquid tape can get messy. but ive used it on cars and trucks from the late eighties through late nineties because the heat and oil get to the insulation and some times you can just get in to the broken part without removing a major part. just make sure there isn't any oil on the wire first.

zubzub · October 18, 2015, 08:23:51 AM

Quote from: jackhanow on October 18, 2015, 07:38:04 AM
i would get some liquid tape and colored electrical tape and carefully reinsulate the wires most likely the wires are good where they havent been disturbed. the liquid tape can get messy. but ive used it on cars and trucks from the late eighties through late nineties because the heat and oil get to the insulation and some times you can just get in to the broken part without removing a major part. just make sure there isn't any oil on the wire first.

.
I agree with this to a point, but on an old 04 the wires casing is so crumbly they will short inside a conduitbwithout movement. By all means, try the liquid tape etc...see if it is s I'll shorting...
Another thought, replace the bulbs and socket with led stuff, this will reduce the load (maybe hide a problem) but you will also not need to go back. Led sockets are affordable online.