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I've been pouring through wiring diagrams and fuse box diagrams, comparing the Excursion to SD trucks. If I go the "piece one together" route, here is what I've learned so far:
The 1999 SD harness is a 1-year harness. I *could* use it, but it will present additional headaches (lack of some wires, additional other wires, funky pin-outs, etc). The 2000-2001 SD harness would be a much better donor harness, as it better aligns with my 2000 Excursion.
With very minor modification, I could throw in a 2000-2001 SD harness (with the SD underhood fuse box) and it WILL work. I'd just lose power to a few things, such as the rear wiper and washer, defrost grid, rear HVAC, quarter flip window motors and all power points except for the dash.
I could also easily take the 2000-2001 SD harness and swap on an Excursion underhood box, and with no further modification, have it run. I'd still be powerless on the accessories I just mentioned, but the correct box would be there to add those circuits in.
My memory is foggy as to what was cut on the Excursion harness I looked at locally. I want to say the engine plugs were cut, and maybe the plugs to the transmission harness and rear light harness. If that is the case and NOTHING ELSE IS CUT, I can lay those bits of an SD harness right in while keeping the "Excursion bits" of the Ex harness- and end up with what I need.
I'll update when I go back and look at that harness.
Okay, so I decided to do it the hard way, since everyone wants to see my head get more gray...
Picked up the Excursion harness (the one that's been cut on) from the yard today. The important Excursion-only stuff was there- the fuse box and all three firewall plugs. Nothing was cut or damaged in that area. So, I have all the correct wiring- undamaged- to power all the Excursion-only goodies.
What *IS* cut on this harness:
1- The two plugs that feed the engine harness (it was actually cut close to the main harness, so a little wire was taken as well).
2- The plugs that feed the transmission and transfer case.
3- The plugs that feed the harness for tail lights, trailer tow and fuel pump.
Luckily, all of these items will be included with a SD pickup harness. All I have to do now is get a harness out of an 00 or 01 pickup, remove it's fuse box and pin it into the Excursion box.
On a side note, what idiot designer at Ford thought it would be a good idea to terminate the wiper plug where they did? I spent more time getting to that plug than any other...
I dug up this pic from my collection of random Ex/SD photos:
In the pic above, there are 5 plugs under the master cylinder area: 4 square plugs (2 gray, 2 black- you can't hardly see the top black one) and one roundish gray plug.
Two of the 16-pin square plugs go to the transmission harness (I'm talking the Ex harness with 4x4. A 2-wheel drive might only have one plug due to not having a transfer case. But I'm not familiar with the 2-wheel tranny harness). These connectors are the C103 and C1044- C103 carries transmission wiring and C1044 carries mostly transfer case wires. These would be on the harness your ad says you are keeping, but if you'd want to part with the engine bay side of these connectors, I'd take them. On the harness I just got, the wires were cut up where they merge into the main harness.
The other two square plugs are C1045 (16 pin) and C1046 (12 pin). The C1045 is the important one for me- it carries rear lighting wires and fuel pump wires. Again, mine was cut on the engine bay side where it merges into the main harness. On the other side (where it goes down under the truck), I need about 2 feet of wiring where mine burned. The C1046 carries trailer/camper adapter wires. I can't tell from your pics if your truck has this one. I don't know if flatbeds have the same setup. But if it does, it's the same story as the C1045- cut at the merge on the engine bay side, burned wires about 2 feet on the under-truck side.
The roundish plug is C1047, and chances are good that your truck either doesn't have it at all, or you'll have just one side of it with nothing plugged into the other side. It carries wires for parking aid and running board lamps. Same story as the above, but this is probably the least important plug for me right now.
As I mentioned, the harness I grabbed has some things cut. I've been working on the passenger side of the harness, since my original (burned) harness was unharmed on the passenger side. The harness I grabbed did have the blower resistor plug cut off, so I went to work.
On the passenger side, the grounds to the passenger side lights, cruise servo, the blower resistor plug, etc-- ALL go to the body ground on the passenger side. These grounds DO NOT go across the firewall to join other grounds. I started by removing this ground system from my original harness- taking them out of the various plugs with a pin pusher and installing it into the new harness.
I then removed the wires to the resistor plug from my original harness- taking enough extra wire that I can make my solder connections to the new harness somewhere along the middle-right firewall- so the connections won't be close to the actual connectors AND so I can stagger them some so they all aren't in the same location, causing a lump in the harness.
Once I get the connections soldered and heat-shrinked, I can re-wrap the harness from the wiper motor connector, all the way through the passenger side.
I now need to locate the two engine connector plugs with as much extra wire as possible, and BOTH SIDES of the plugs going under the truck with as much extra wiring on the engine side as possible and a foot or two on the other side.
This would be a lot better with a good harness to begin with, but there is no way I'm paying what people are asking for them. Almost no one needs these, most get scrapped, and I feel that as soon as someone does want one- people want to stick it to them for some extra bucks. The yard I always use told me that if they get one, I can have it for $50. I can have it with the trans harness and the harness going back to the rear lights for $75. So, I'll just solder this one up for now until they get an Ex in. That's a heck of a lot better than the 2 and 3 hundred dollar quotes people have been giving me...
Sorry man I have been out of town for work for the past two weeks. I get home Monday and should be able to grab as much harness as I can and ship it to you. Pm me your address and I will get it out next week.
I have the passenger side of the harness rebuilt from a little past the wiper motor on over. The only plug I'm missing for what I've done so far is the hood light plug. No biggie- it seems I never have a vehicle with a hood light anyway...
In addition to the plugs I mentioned being missing in my last post, I'm also missing the plug at the master cylinder (the one with three wires) and the driver side ABS sensor plug (and possibly some of the wire- I don't know how long it is supposed to be).
At least half of the harness is looking good! My soldering skills seem to be improving, haha.
My haynes manual doesn't seem to be too helpful. I need pics or descripts of where hoses go-- from the intake all the way over to cover the entire driver side.
Things seem to be a lot different than my 99 V8 truck.
Not the best picture but you are getting the fusebox all firewall connectors, all connectors for the harnesses under the hood, the tail light harness all the way back to the speed sensor on the rear axle, and i think it is to the center of the firewall passed the wiper motor.
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