Painless Performance 20121 Wire Harness Installation Instructions
The Painless Performance Products Wire Harness 20121 is a complete wiring system designed for 1967-1968 Ford Mustangs. This harness includes all the necessary wires and connectors to replace the original factory wiring, complete with a built-in anti-theft feature. The harness is color-coded and marked for easy identification. The kit also includes pre-installed fuses, relays, and terminals for a streamlined installation experience.
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Wire Harness Installation
Instructions
For Installing:
Part #20121
14 Circuit
1967 – 1968 Ford Mustang
Manual #90556
Perfect Performance Products, LLC
Painless Performance Products Division
2501 Ludelle Street
Fort Worth, TX 76105-1036
800-423-9696 phone – 817-244-4024 fax
Web Site: www.painlessperformance.com
E-Mail: [email protected]
If you have any questions concerning the installation of this harness or having trouble in general, feel free to call Painless
Performance Products' tech line at 1-800-423-9696. Calls are answered from 8am to 5pm central time, Monday thru Friday, except holidays.
We have attempted to provide you with as accurate instructions as possible, and are always concerned about corrections or improvements that can be made. If you have found any errors or omissions, or if you simply have comments or suggestions concerning these instructions, please write us at the address on the cover and let us know about them. Or, better yet, send us a fax at (817) 244-4024 or e-mail us at [email protected]. We sincerely appreciate your business.
Perfect Performance Products, LLC shall in no event be liable in contract or tort (including negligence) for special, indirect, incidental, or consequential damages, such as but not limited to, loss of property damage, or any other damages, costs or expenses which might be claimed as the result of the use or failure of the goods sold hereby, except only the cost of repair or replacement.
P/N 90556 Painless Wiring Manual
March 29th, 2005
Copyright
© 2005 by Perfect Performance Products, LLC
TABLE OF CONTENTS
1.0 Introduction
2.0 About Instructions…………………………………………………………………..……………………………..1
3.0 Contents in The Painless Wire Harness Kit………………………………………………………………………….2
5.0 Pre-Installation and Harness Routing Guidelines………….………………………………………………………3
6.0 Harness Installation Instructions………………………………………………………………………………………..4
6.2
6.3
6.4
6.5
General
Attachment
Grounding The Automobile
Terminal Installation and Making Connections
Testing The System
7.0 Specific Circuit Connections……………………………………………………………………………………………….10
7.1
7.2 High Amperage Alternator Kit
7.3
7.4 Headlights/Front Turn Signals/Park Lights/Horns
7.5 Rear Light Section
7.6 Steering Column Wiring - Turn Signal Connections
7.7 Ignition Switch Connections
7.8 Headlight
7.9 Lights
7.10 Gauge Cluster Section
7.11
7.12 Wiper Switch/Coordination Switch/Dimmer Switch/Wiper Motor
7.13 Interior Lighting and Accessories
8.0 Wire Connection Index and Fuse Requirements……………………………………………………………………23
Table 8.1
Table 8.2
Table 8.2
Table 8.2
LIST OF TABLES
Fuse Requirements………………………………………………………………………………………………..23
Wire Connection Index (1 of 6)…………………………………………………………………..………….24
Wire Connection Index (2 of 6)……………………………………………………………………..……… 25
Wire Connection Index (3 of 6)……………………………………………………………………………...26
Table 8.2
Table 8.2
Table 8.2
Wire Connection Index (4 of 6)……………………………………………………………………………...27
Wire Connection Index (5 of 6)……………………………………………………………………………...28
Wire Connection Index (6 of 6)…………………………………………………………..………………….29
Painless Performance Products recommends, you the consumer, read this installation manual from front to back before installing this harness. Due to the variables in modifications done to these classic 1967 and 1968 Mustangs, reading this manual will give you considerable insight on the proper installation of this harness in an original or modified application.
Included in this kit is a sheet of pre-printed labels, to assist in identifying connections as the existing harness is removed from the vehicle.
1.0
INTRODUCTION
You have purchased what we at Painless Performance Products believe to be the most up-to-date and easiest-to-install automotive wire harness on the market. It is designed for easy installation, even if you have no electrical experience
All Kits have a built-in-anti-theft feature. Removing the fuse labeled “coil” from the fuse block will prevent the vehicle from starting.
The proper fuses have been pre-installed in the fuse block. In addition, all wires are color-coded and marked for easy identification. This will help you identify the different circuits during installation and later on if additions to the overall system are necessary. For fuse specifications and wire color designations, see Section 8.1 and Table 8.1.
This Painless wire harness is designed to be used in 1967 - 1968 Ford Mustangs. All wire is 600 volt,
257 °F, TXL. Standard automotive wire is GPT, 300 volt, 176°F, with PVC insulation.
This complete Classic Mustang wiring system has been designed with six major sections incorporated into it:
ENGINE SECTION: Water temperature, oil pressure, tachometer, coil, choke, a/c compressor clutch coil
HEADLIGHT SECTION: Includes high beam, low beam, park lights, right turn, left turn, horns, voltage regulator, starter solenoid, battery feed and alternator.
GAUGE CLUSTER SECTION: Includes wires to connect to the gauges and to the indicator lights.
UNDER-DASH SECTION: Includes wires to connect heater-a/c switch, headlight switch, turn signal switch, radio, tachometer, ignition switch, cigar lighter, dimmer switch, brake switch, heater-a/c resistor, a/c blower motor, wiper motor, wiper switch and wiper coordination switch.
INTERIOR LIGHTING SECTION: Includes right and left door jam switches, shift indicator light, courtesy lights, and glove box.
REAR LIGHT SECTION: Includes taillights, stoplights, left and right turn signals, trunk light, backup lights, license plate light, and fuel sending unit.
2.0
ABOUT THESE INSTRUCTIONS
The contents of these instructions are divided into major Sections, as follows:
1.0 Introduction
2.0 About These Instructions
3.0 Contents of Painless Wire Harness Kit
4.0 Tools Needed
5.0 Pre-Installation and Harness Routing Guidelines
6.0 Harness Installation Instructions
7.0 Specific Circuit Connections
8.0 Wire Connection Index and Fuse Requirements
Sections are divided into subsections and Paragraphs. Throughout these instructions, the Figure numbers refer to illustrations and the Table numbers refer to information in table form. These are located in Sections or Paragraphs corresponding to the number. Always pay special and careful attention to any
Notes, especially those in the Tables, and any text marked Caution.
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3.0 CONTENTS OF THE PAINLESS WIRE HARNESS KIT
Refer to the list below to take inventory of all the parts in the kit. If anything is found to be missing, contact the dealer the kit was purchased from or Painless Performance at (800)423-9696. The 1967/1968 Mustang
Wire Harness Kit should contain the following items:
• The Main Wire Harness, with Fuse Block pre-wired fuses and relays installed.
• Pig Tails: Headlight Connector Harnesses, A/C Harness, Cluster
Harness, Front Lights Ground Harnesses, Tail Ground Harness and
1968 Turn Signal Harness.
•
Bag Kit: 1 pkg. of small and 1 pkg. of large Nylon Tie Wraps, Ballast
Resistor, Maxi Fuse, Firewall Grommets, 1968 Ignition Switch and a
Fuse Identification Label.
•
Parts Box containing Terminals, Splices, Spare Fuses etc.
Figure 3-1 Painless Wire Harness Kit
4.0 TOOLS NEEDED
In addition to basic hand tools the following will also be needed:
• Crimping Tool
• Wire Stripper
Note: Use a quality tool to avoid over-crimping.
• Test Light or Volt Meter
• Small (10 amp or less) Battery Charger
2
5.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES
Installation of this wire harness consists mainly of two parts:
• The physical routing and securing of the wire harness.
• The connection of the individual circuits to their components.
These two major tasks are not separate steps, but are integrated together. In other words, you will route a section of wires and make that sections connections. Route the next section of wires and make those sections connections. The layout of this 1967-
1968 Mustang harness will dictate how to physically route the harness in your automobile. The breakouts and connections are very close to the original Ford harnesses and should fit just as well if not better. It’s a good idea to document how the original harness was routed as this new one follows most of the same routing. The fitment greatly depends on to what extent you want to secure and conceal the harness.
Painless offers some general guidelines and routing practices starting in Section 5.2,
GENERAL installation instructions in Section 6.0, and precise instructions concerning the electrical connections you will make in Section 7.0. To help you begin thinking through the installation of your wire harness please read the following sections:
5.1 Familiarize yourself with the harness by removing the harness from the box, laying it out on a table or on the floor and locating each of the harness sections in the following list. Whenever a particular harness section is referred to in these instructions it is shown in "all caps": ENGINE SECTION.
ENGINE SECTION
HEADLIGHT SECTION
GAUGE CLUSTER SECTION
UNDER-DASH SECTION
INTERIOR LIGHTING
SECTION
REAR LIGHT SECTION
5.2 It is recommended to route the harness through and around open areas inside the car. Inside edges provide protection from hazards and also provide places for tie wraps, clips, and other support.
5.3 Route the harness away from sharp edges, exhaust pipes, hood, trunk and door hinges.
5.4 Plan where harness supports will be located. Allow enough slack at places where movement could occur (body to frame, frame to engine, etc.)
5.5 At wire ends, don't depend on the terminals to support the harness. The weight of the harness could cause terminals to disconnect or copper wire strands to break.
5.6 The wires should be bundled into groups. Use nylon ties, poly split loom, or tape.
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6.0 HARNESS INSTALLATION INSTRUCTIONS
6.1 General Installation
CAUTION: DISCONNECT THE POWER FROM YOUR VEHICLE BY
REMOVING THE NEGATIVE (BLACK) BATTERY CABLE FROM THE
BATTERY.
Note: Be sure to retain Convertible Power Top wiring and Overhead
Console wiring when removing the old harness. Circuits for these
accessories are not included in this harness.
6.1.1 Mount the base in the stock fuse block location with two of the self tapping screws from the parts kit. See Figure 6-1.
Figure
4
Figure 6-3 Routing Fuse Block through Instrument Cluster Opening
6.1.2
Route the fuse block and attached harness through the instrument cluster opening, down past the wiper motor and snap it into the fuse block base.
See Figure 6-3 and Figure 6-4. (Note: The fuse block does not need to be grounded.)
Figure 6-4 Fuse Block Snapped Into Base
6.1.3 Route the harness across the cluster opening from right to left, down through the opening under the headlight switch and to the floor pan. Carefully remove any extra slack in the harness. Reuse the clamp which held the original harness to the dash.
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6.1.4 Locate the smaller of the two grommets included in the parts kit. Install this grommet into the hole which is directly to the left of the brake master cylinder when facing the firewall. Locate and gently pull the ENGINE
SECTION wires through the firewall. See Figure 6-5.
Figure 6-5 Engine Section Firewall Grommet
6.1.5 Now locate the Rear Light Section of the harness. This section of the harness will be routed down through the A-pillar; through the sill plate, through the B-pillar, over the driver’s side quarter panel wheel well and into the trunk. See Figures 6-6 thru 6-9. Note: In figure 6-8 the original
harness is being taped to the new harness to aid in pulling the Rear
Light Section through the quarter panel and into the trunk.
Figure 6-6 Figure 6-7
Figure 6-8 Figure 6-9
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6.1.6 The final main section of the harness to be pulled is the Headlight Section.
This section of the harness is to be fed through the hole in the firewall which is directly to the right of the master cylinder. After this section has been pulled through, carefully install the large grommet from the parts kit into the hole. See Figures 6-10 and 6-11.
Figure 6-10 Figure 6-11
6.1.7 Attach the harness to the shock tower using the provided zip ties or using the original clamps. Route it through the radiator core support holes and across the front of the car. Note: This new harness is designed to be routed in
the stock harness location. See Figures 6-12 thru 6-15.
Figure 6-12 Below Voltage Reg. Figure 6-13 Front Core Support
Figure 6-14 Pass. Side Core Support Figure 6-15 Pass. Side Core Support
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6.2 Harness Attachment
Harness routing and shaping is and should be a time-consuming task. Taking your time will enhance the beauty of your installation.
Please be patient and TAKE YOUR TIME!
6.2.1 Mold the harness to contour the firewall, fenders, core support or any other areas where wires or harness sections are routed. Remember to route the harness away from sharp edges, exhaust pipes, hood, trunk, and door hinges.
6.2.2 Attach harness groups to your automobile with clips or zip ties starting at the fuse block and working you way towards the outer harness circuits. The dash wires should be routed out of the way of any under-dash obstacles, such as vent levers, air conditioning controls, radio, etc.
Note: Do not tighten tie wraps and mounting devices until each individual connection has been made on the particular circuit to be wire tied. Make all harness attachments LOOSELY, until all connections are made in each section.
6.2.3 When using wire loom on the visible areas of the harness, it will need to be wire tied every 12" or so. This will make a very attractive assembly. Under the dash a tie installed every 6" or so will hold the wires in place nicely.
Remember to take your time.
6.3 Grounding the Automobile
This Painless Wire Harness Kit includes the following ground wires: two front lights ground harnesses, one tail ground harness, one built-in ground wire for the horn, one ground wire on the cluster harness and a ground wire for the accessory relay. Any additional circuits or accessories requiring a ground will have to be added.
6.3.1 Connect a Ground Strap or Cable (even a 10-gauge wire is too small) from the Negative Battery terminal to the automobile frame.
6.3.2 Connect a Ground Strap from the Engine to the frame. DO NOT RELY
UPON THE MOTOR MOUNTS TO MAKE THIS CONNECTION.
6.3.3 Connect a Ground Strap from the Engine to the Body.
6.4 Terminal Installation and Making Connections
Note: In the following steps you will be making the circuit connections. Before you start, you should carefully read Sections 7.0, as appropriate, and refer to
Section 8.0 as needed, DOUBLE-CHECKING your routing and length calculations
before cutting any wires and making connections. The majority of the harness has been pre-terminated.
6.4.1 Have all needed tools and connectors handy.
6.4.2 Select the correct size terminal for the wire application.
6.4.3 Determine the correct wire length and cut the wire. Remember to allow enough slack in the harness and wires at places where movement could possibly occur, such as automobile body to frame, frame to engine, etc.
Double-check your calculations.
8
6.4.4 Strip the insulation from the wire. Strip only enough necessary for the type of terminal you are using. All of the terminals included in this kit require a ¼” strip length.
6.4.5 Insert the stripped portion of the wire into the crimp side of the terminal. Be careful as to not allow the individual wire strands to fray during insertion.
6.4.6 Crimp the terminal onto the wire using the proper jaw location on the crimpers.
Note: In step 6.4.6 be sure to use the proper jaw location on your crimpers.
Most crimping tools have it color coded for which cavity to use. 18-22ga – Red,
16-14ga – Blue, and 12-10ga – Yellow. CAUTION: DO NOT OVER-CRIMP!
6.4.7 Many connections will be made throughout the installation process. Make sure each wire is FIRST properly routed and THEN attach. DO NOT ATTACH
FIRST AND ROUTE AFTERWARD.
6.4.8 After all wires are terminated and securely attached, tighten the mounts and/or zip ties to secure the harness permanently.
6.5 Testing The System
6.5.1 Use a small (10 amp or less) battery charger to power up the vehicle for the first time to test the circuits. If there is a problem anywhere, the battery charger's low amperage and internal circuit breaker will provide circuit protection.
CAUTION: IF YOU HAVE NOT YET DISCONNECTED THE BATTERY
FROM THE AUTOMOBILE, DO SO NOW! DO NOT CONNECT THE
BATTERY CHARGER WITH THE BATTERY CONNECTED.
6.5.2 Connect the battery charger's NEGATIVE cable to the automobile chassis or engine block and its POSITIVE cable to the automobile's positive battery terminal lug.
6.5.3 INDIVIDUALLY turn on each light, ignition, wiper circuit, etc. and check for proper operation.
Note: The turn signals will not flash properly if you do not have both the front and rear bulbs installed and connected.
6.5.4 After all circuits have been checked, disconnect the battery charger and attach the vehicles battery cables to the battery. REPEAT STEP 6.5.3.
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7.0 SPECIFIC CIRCUIT CONNECTIONS
7.1 Alternator/Regulator/Solenoid See Figure 7-1.
7.1.1 Connect HEADLIGHT SECTION wire #915 (Blk/Ylw) to the Alternator
Output post marked “Bat” or “B+”. See Figure 7-2
7.1.2 Connect HEADLIGHT SECTION wire #914 (Wht) to the Alternator post marked “FLD”. See Figure 7-2
7.1.3 Locate the Voltage Regulator Connector in the HEADLIGHT SECTION and plug it in to the Voltage Regulator, which is on the driver’s side engine compartment on the core support.
7.1.4 Connect the yellow wire with the preinstalled female bullet connector to the Noise Capacitor.
7.1.5 Locate the Maxi Fuse Base in the parts kit and attach it to the passenger side shock tower. See Figure 7-3
7.1.6 Connect HEADLIGHT SECTION wire #916 to one side of Maxi Fuse Base.
Using the remaining portion of wire #916 connect the other side of the
Maxi Fuse Base to the Battery side of the starter solenoid. See Figures
7-1, 7-3, & 7-4.
Figure 7-1 Alternator/Regulator/Solenoid Connections
Figure 7-2 Alternator Connections
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Figure 7-3 R.H. Shock Tower Figure 7-4 Wire #916 Connection
7.2 High Amperage Alternator Kit
7.2.1
If an alternator with an output of more than 65 amps is being installed, a
Painless High Amperage Alternator Kit, Painless P/N 30709, will need to be purchased.
7.3 Engine Section See Figure 7-5.
7.3.1
Connect ENGINE SECTION wire #920 to one side of the ballast resistor.
Connect the other side of the ballast resistor to the positive post on the ignition coil.
Note: If using a ballast resistor be sure to mount it away from other wiring and hoses. It gets very hot during operation.
7.3.2
ENGINE SECTION wire #970 is used both on a point’s type ignition system and a Duraspark II System. It is to be connected directly to the positive post on the ignition coil or the coil feed side on the ballast resistor. The other end is to be connected to the “I” terminal on the starter solenoid. See Figure 7-
5.
7.3.3
Connect ENGINE SECTION wire #919 to the “S” terminal on the starter solenoid. If using a Tachometer, connect ENGINE SECTION wire #923 to the negative side of the ignition coil. See Figure 7-5
Figure 7-5 Points Type Ignition Diagram
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7.3.4
Connect ENGINE SECTION Temperature Sending Unit wire #921 to the engine temperature sending unit. Connect ENGINE SECTION Oil Pressure
Sending Unit wire #922 to the engine oil pressure sending unit. Connect the
ENGINE SECTION Electric Choke B+ wire #954 to the electric choke.
Figure 7-6 Ford Duraspark II Systems (Ford Electronic Ignition)
7.3.5
Neutral Safety/Backup Light Switch wire #’s 958, 956 and 919 (2 wires) all breakout from the firewall in the ENGINE SECTION. #958 is the power source to the switch for the backup lights and #956 is the wire connected to the actual bulbs. Wire IGNITION SWITCH START #919 comes from the start terminal on the Ignition Switch and provides the start signal to the Neutral
Safety switch. Wire STARTER SOLENOID #919 carries the start signal from the
Neutral Safety switch to the Starter Solenoid. See Figure 7-7.
Figure 7-7 NEUTRAL SAFETY SWITCH
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7.4 Headlights/Front Turn Signals/Park Lights/Horns
Figure 7-8 Front Lights and Horns
7.4.1 Locate the pre-terminated Headlight Pigtails and the Front Lights Ground
Harnesses in the parts kit. Install one of the Headlight Pigtails onto each headlight. Feed the wires from each pigtail through the body and core support down to the back of the turn signal housings in each wheel well.
7.4.2 *The Front Lights Ground Harness has one 14 gauge wire and two 18 gauge wires. One end of the 14 gauge wire is pre-terminated and will need to be connected to a body bolt. See Figure 7-9. The other end of the 14 gauge wire is for the headlights ground. The two 18 gauge wires are to be connected to the
Turn/Park Lamps ground and to the Side Marker Lamps ground. See Figure 7-8.
Figure 7-9 Front Lights Ground Harness
13
Note: Some Mustangs had turn signal indicators on the hood. These lights are supported through this harness by connecting them to the #926 Left Turn Signal wire and the #925
Right Front Turn Signal wire. These wires are located just inside the vehicle past the main grommet on the firewall in the Headlight Section.
7.5 Rear Light Section
7.5.1
The REAR LIGHT SECTION consists of: Taillights, Stoplights, Left and Right
Turn Signals, Trunk Light, Backup Lights, License Plate Light, and Fuel
Sending Unit.
Figure 7-10 Rear Light Section and Dome Light
7.5.2
Locate and connect the Tail Ground Harness as shown in Figure 7-10. The wires in this section are to be routed in the same location as the stock harness. Use the metal tabs under the rear trunk opening lip to secure the harness.
See Figure 7-11.
14
Figure 7-11 Trunk Wiring Tabs
7.6 Steering Column Wiring-Turn Signal Connections
7.6.1
If wiring a 1967 Mustang the original Turn Signal Switch Connector will plug directly into the new Painless harness. The only additional connection to be made is to attach the pre-terminated Horn Switch Ground. See Figure 7-12.
7.6.2
If wiring a 1968 Mustang the original Turn Signal Switch Connector from the old harness will need to be re-used. Carefully remove the original wires, ONE
WIRE AT A TIME, replacing them with the new wires in the 1968
Mustang Turn Signal Adaptor Pigtail. The pigtail colors match the
original colors in the old harness. Use small pair of needle nose pliers or a flat screwdriver to remove the original terminals from the connector cavities. See Figure 7-12.
Figure 7-12 Turn Signal Connectors
15
Figure 7-13 Original Turn Signal Connector Figure 7-14 ’68 Adaptor Pigtail Wires
7.7 Ignition Switch Connections
7.7.1
Connect the IGNITION SWITCH wires to the new supplied Ignition Switch as illustrated in Figure 7-15. Use the two 10-24 machine nuts included in the parts kit, to attach the #932 Blk/Grn wire.
Figure 7-15 Ignition Switch Connections
16
7.8 Headlight
7.8.1 Connect the HEADLIGHT SWITCH wires as illustrated in Figure 7-16. After completing the installation of the Headlight Switch wires locate the DASH GROUND
#969 wire, which is directly above the steering column in the main body of the harness and connect it to the chassis ground screw behind the gauge cluster.
Figure 7-16 Headlight Switch Connections
7.9 Brake Lights Switch
Route the BRAKE SWITCH wires #917 Brake Switch B+ (Grn/Red) and #918
Brake Switch Output (Grn) over the steering column and down to the Brake
Switch located on the brake pedal. Leave enough slack in the wires to allow for the brake pedal movement. These wires are not polarity specific, in other words it does not matter which wires goes onto each side of the switch.
See Figure 7-17.
Figure 7-17 Brake Switch
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7.10 Gauge Cluster Section
Right Turn
Temp
Brake
Gauge
Illumination
Oil Pressure
Gauge
Clock
Wiper Switch
Voltage Reg.
Left Turn Fuel
Gauge
Ammeter
High Beam
Figure 7-18 Gauge Cluster 1967 Mustang
Illumination
7.10.1 The Gauge Cluster on the 1967 Mustang has each wire color stamped into the metal next to each connection, with exception of the illumination light sockets. The Painless Gauge Cluster harness in this kit was designed to match these designations.
7.10.2 With the Gauge Cluster positioned as in Figure 7-18 and the harness completely installed, the 15 way connector on the Cluster Harness will be directly above the two terminals for the fuel gauge.
7.10.3 The illumination wires are (Blue/Red) and (Blk). Each of the illumination light sockets has one of each of these wires. There are a total of seven of these light sockets. Lay the harness over the cluster and route and install each of the illumination sockets. See Figure 7-18.
Note: If wiring a 1968 Mustang be sure to read
7.10.11
before going any farther.
7.10.4 The temperature gauge is on the far left. Connect the (red/wht) wire to the left post and the (blk/grn) wire to the right post.
7.10.5 The oil pressure gauge and amp meter are in the same gauge pod. Connect the (wht/red) wire to the left post on the oil pressure gauge and the (blk/grn) wire to the right post. On the amp meter, connect the (ylw) wire to the left post and the (red) wire to the right post.
7.10.6 Next install the light socket with a (wht/blu) wire and a (blk) wire into the right hand turn signal indicator hole. Now locate the light socket with a
(red/ylw) wire and a (pur) wire. This socket is for the Brakes indicator lamp.
Note: On 1967 and 1968 Mustangs the amp meter is a shunt type. What this means is this type of amp meter only uses a sample of the current in the charging system as opposed to handling all the current. As wired per the original
Mustang harnesses, these shunt type amp meters will only read a discharge.
Even with the engine running and the charging system working properly the amp meter will be measuring the draw on the vehicles harness. The amp meters in the ’67-’68 Mustangs are simply not going to indicate a charge.
18
NOTE: To check the Mustangs charging system, after the entire harness has been installed, connect a DC voltmeter across the battery with the engine running. A good charging system will measure between 13-14.5 volts. This voltage measurement can be affected by different sized pulleys and different engine idle rpms.
7.11
7.10.7 If so equipped, the single (lt blu/blk) wire is to be connected to the back of the clock. If a clock is not going to be connected, tape up and stow this wire with electrical tape.
7.10.8 Locate the socket with a (lt grn/blk) wire and a (blk) wire and install it into the high beam indicator hole.
7.10.9 Remove the Voltage Regulator mounting nut and install the single black wire with the ring terminal. Next locate the male spade terminal crimped on the end of two (blk/grn) wires and connect it to the left terminal on the voltage regulator. The female spade terminal with one (blk/grn) wire goes onto the right terminal of the voltage regulator.
7.10.10 Next install the light socket with a (grn/wht) wire and a (blk) wire into the left hand turn signal indicator hole. The last two wires are for the Fuel Gauge.
The (ylw/wht) goes onto the left post and the (blk/grn) on the right post.
This completes the Gauge Cluster Section.
7.10.11 The difference between a 1967 Mustang Gauge Cluster vs. a 1968 Mustang
Gauge Cluster is the location of the Fuel Gauge and the Oil Pressure Gauge.
These two gauges are in the opposite location on a 1968 as compared to a
1967. Because of this the two wires that will be different are the (wht/red) and the (ylw). Be sure to install the (wht/red) on the Oil Pressure Gauge left hand post and the (ylw) on the Fuel Gauge left hand post.
Figure 7-19 Blower Motor/Blower Motor Resistor/Blower Motor Switch
7.11.1 The connections for the Blower Motor, Blower Motor Resistor and Blower
Motor Switch in a Mustang with a Heater ONLY are illustrated in Figure 7-
19. The ground for the Blower Motor Switch is internal to the switch, meaning there are no connections to be made. The wire colors on wire numbers 973, 974, & 975 all match the wire colors coming out of the switch.
The wire #976 (ylw) connects to the Orange wire on the blower motor. The wire #967 (brn) connects to the Black wire on the blower motor.
19
7.11.2 On all Mustangs equipped with add-on or factory Air Conditioning the included
A/C Harness must be installed. See Figure 7-20.
Figure 7-20 Heater with Air Conditioning
7.11.3 Figure 7-20 has both the Air Conditioning control harness and the Blower
Motor wiring. Be sure to read the wire identification on each wire and connect the wires to the correct components.
7.12 Wiper Switch/Coordination Switch/Dimmer Switch/Wiper Motor
Figure 7-21 Wiper Switch Connections
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Figure 7-22 Coordination Switch
7.12.1 The connections for the Wiper Switch in the cluster are illustrated in Figure 7-
21.
7.12.2 The connections for the Coordination Switch on the floor near the drivers kick panel are illustrated in Figure 7-22. The Coordination Switch wires and the
Headlight Dimmer Switch wires are bundled together. After connecting the
Coordination Switch wires, connect the following for the Dimmer Switch: Dimmer
Switch B+ #907 to the center spade terminal, Dimmer Switch (Low Beams)
#909 and Dimmer Switch (High Beams) #908 each to one of the outside spade terminals.
Figure 7-23 Wiper Motor Plug
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7.12.3
The connections for the Wiper Motor are illustrated in Figure 7-23. Be sure to note the cavities for wire #979 and #977 are female and for #985 and
#982 are male bullets.
7.13 Interior Lighting and Accessories
7.13.1 The interior lighting circuit is activated by three different switches. One switch is located inside the headlight switch and the other two are located in each door jamb. The door jamb wires for each switch are pre-terminated and will plug directly into the 1967 style Mustang door jamb switches. The switches on the 1968 Mustang use a different style terminal and will require splicing onto the original switch connectors. One #987 and one #988 wire connect to each of the door jamb switches. All are marked for which door jamb switch they connect to and are not polarity specific.
7.13.2 The interior lights supported by this harness include: both Left and Right
Hand Courtesy Lights (#989) under the dash, Dome Light (#945), Trunk
Light (#946), and if so equipped both “B” pillar lights. The “B” pillar lights are located in the interior panels behind the driver and passenger front seats. To power these, use the splice on each of the door jamb switches #988 wires.
7.13.3 The Glove Box Light Switch B+ #990 connects to the glove box light. Cigar
Lighter B+ #903 connects directly to the Cigar lighter power terminal.
7.13.4 The Console Light B+ #930, Radio Light B+ #930, the Tachometer Light B+
#930, and the Gauge Cluster Illumination Lights are all controlled by the
Headlight Switch dimmer circuit when the Headlights or Park lights are ON.
Each wire description dictates the component to connect them to.
7.13.5 Constant Radio B+ #940 is to be connected to the Memory or Constant input on an aftermarket stereo. (Most CD players with a clock require this input)
The Switched Radio B+ #941 is another wire required on most stereos.
7.13.6 If a Tachometer is to be installed use wires: Tachometer B+ #966,
Tachometer Signal #923 and the Tachometer Light B+ #930 wire described in step 7.13.4.
7.13.7 The final Accessory component in this Mustang chassis harness is a 20amp accessory relay output. The relay is preinstalled in the fuse block, powered, and fused. See Figure 7-24.
Figure 7-24 Accessory Relay Diagram
22
8.0 WIRE CONNECTION INDEX AND FUSE REQUIREMENTS
8.1 Wire Connection Index
In each section, connect the wire, as identified by its wire color, to the appropriate item in the Wire Ending Point column.
Table 8.2 is divided into sections that correspond to the sections of your wire harness. (ENGINE SECTION, HEADLIGHT SECTION, GAUGE CLUSTER
SECTION, UNDER DASH SECTION, INTERIOR LIGHTING SECTION, AND REAR
LIGHT SECTION) The index is divided vertically into six columns. COLOR,
GAUGE, NUMBER, WIRE PRINT, WIRE STARTING POINT, and WIRE ENDING
POINT.
The information in these columns are for reference to help identify where each wire and what it needs to be connected to. These columns tell where each wire originates, the wire number, its function and which section of the harness the wire is in.
The column labeled NO. contains a 900-series number used to identify the wires in the diagrams in Section 6.0 and 7.0 of this manual.
The wire numbers which occur TWICE in this index indicate the connection of
BOTH ENDS or a splice of wires inside the harness. Most wire segments are pre-connected at the WIRE STARTING POINT such as all the wires originating from the fuse panel. The WIRE ENDING POINT is where that wire needs to be connected.
Table 8.1 Fuse Requirements
23
Wire
Starting
Point
Wire Ending Point
ENGINE SECTION
Red 18 954 Electric Choke B+ Fuse Block Electric Choke
Red/Grn 14 920 Coil B+
Red/Wht 18 921 Temperature
Fuse Block
Temperature
Gauge
Coil “+”
Temperature
Sending Unit
Pressure Oil Pressure
Gauge
Brn 16 Ignition Starter
Solenoid “I”
Post
Red/Ylw
Blk/Red
18
18
923
958
Tachometer Signal
Back-Up Light Switch B+
Blk/Red 18 956
Red/Blu 14 919
Oil Pressure
Sending Unit
Coil “+”
Tachometer
Fuse Block
Coil “-“
Neutral
Safety/Back-Up
Lights Switch
Back-Up Lights Back-Up
Light Switch
Ignition
Switch
Neutral
Safety/Back-
Up Light
Switch
Neutral
Safety/Back-Up
Light Switch
Starter Solenoid “S”
Post
HEADLIGHT SECTION
Brn 16 Ignition Coil “+” Starter Solenoid “I”
Post
Red/Blu 14 919 Neutral
Safety/Back-
Up Light
Switch
Starter Solenoid “S”
Post
Blk/Ylw 10 916 Battery Source (Maxi Fuse) Fuse Block Starter Solenoid B+
Wht 14 914 Alternator
Regulator
Alternator “FLD”
Post
Blk/Ylw 10 915 Alternator Fuse Block Alternator Output
Post
Blu/Ylw 16 924
Grn/Wht 18 926
Wht/Blu 18 925
Blk/Ylw 18 927
Left Turn Signal
Right Front Turn Signal
Horn Relay
Turn Signal
Switch
Turn Signal
Switch
Headlight
Switch
Left and Right
Horns
Left Front Turn
Signal
Right Front Turn
Signal
Front Park Lights
Pur 18
Table 8.2 Wire Connection Index
Brake
24
Wire
Starting
Point
Wire Ending Point
HEADLIGHT SECTION cont’
Red/Blk 14 909 Dimmer
Switch
Low Beam
Headlights
High Beam
Headlights
Grn/Blk 14 908 Dimmer
Switch
GAUGE CLUSTER SECTION
Wht/Red 18 Connector Pin (1)
Grn/Blk
Blk/Grn
18
18
Blk 18
Ylw/Wht
Blk/Grn
18
18
Connector Pin (2)
Connector Pin (3)
Connector Pin (4)
Connector Pin (5)
Oil Sending
Unit
Dimmer
Switch
Constant
Voltage Unit
Chassis
Ground
Fuel Sending
Unit
Fuse Block
Oil Gauge
High Beam
Indicator
6V Source for
Gauges
Dash Ground
Fuel Gauge
12V to Constant
Voltage Unit
Dash Lights B+
Amp Gauge
Amp Gauge
Blu/Red
Ylw 18
Red 18
(7)
Connector Pin (8)
Wht/Blu
Red/Wht
Pur
Red/Ylw
Blu/Blk
Grn/Wht
Blank
18
18
18
18
18
18
18
Connector Pin (6)
Connector Pin (9)
Connector Pin (10)
Connector Pin (11)
Connector Pin (12)
Connector Pin (13)
Connector Pin (14)
Connector Pin (15)
UNDER DASH SECTION
Headlight
Switch
Fuse Block
Starter
Solenoid
Turn Signal
Switch
Temperature
Sending Unit
Emergency
Brake
Fuse Block
Fuse Block
Turn Signal
Switch
Right Turn Indicator
Temperature Gauge
Brakes Indicator
Light
Brake Light B+
Clock B+
Left Turn Indicator
Blk/Orn 12 928
Headlight Switch
Headlight Switch B+ Fuse Block
Red/Ylw 14 907
Lighting Gauges,
Console,
Radio, and
Tach Lights
Dimmer Switch B+ Dimmer
Switch
Table 8.2 Wire Connection Index 25
Headlight Switch
Terminal “B"
Headlight Switch
Terminal “I”
Headlight Switch
Terminal “H”
Blk/Ylw
Blk
16
14
927
929
934
932
Wire
Starting
Point
UNDER DASH SECTION Con’t
Wire Ending Point
Headlight Switch Cont’
Park Lights
Tail Lights to Headlight Switch
(D1)
B+
(D2)
Park Lights Headlight Switch
Tail Lights
Terminal “P”
Headlight Switch
Terminal “R”
Fuse Block
Dome and
Trunk Lights
Ignition Switch Connections
Headlight Switch
Terminal (D1)
Headlight Switch
Terminal (D2)
Ignition Switch B+
Ignition Switch Accessory
Maxi Fuse
Fuse Block
Ignition Switch
Ignition Switch
Ylw
Blk/Grn
12
14
Red/Blk 14 919
Grn/Wht 18
Wht/Blu 18
Left Hood Turn Signal
Indicator (Optional)
Right
Indicator (Optional)
Neutral
Safety/Back-
Up Light
Switch
Grn/Orn
Wht/Red
Blu
Grn
14
16
14
14
949
Turn Signal Switch
Left Rear Turn Signal Left Rear
Turn/Stop
Light
951 Emergency Flasher Switch B+ Emergency
952
918
Turn Signal Flasher Switch
B+
Brake Switch Output
Grn/Wht 18 926 Left Turn Signal
Turn Signal Switch
Turn Signal Switch
Flasher
Turn Signal Turn Signal Switch
Flasher
Brake Switch Turn Signal Switch
Wht/Blu
Blk
Blk
18
Orn/Blk 14 948 Right
18
18
925
963
963
Right Front Turn Signal
Turn Signal
To Horn Switch
Horn Switch Ground
Left Front
Turn Signal
Right Front
Turn Signal
Turn Signal Switch
Turn Signal Switch
Right Rear
Turn/Stop
Turn Signal Switch
Light
Horn Relay Turn Signal Switch
Chassis
Ground
Turn Signal Switch
Left Hood
Turn
Indicator
Right Hood
Turn
Indicator
Ignition Switch
Turn Signal Switch
Turn Signal Switch
Table 8.2 Wire Connection Index
26
Wire
Starting
Point
UNDER DASH SECTION Con’t
Wire Ending
Point
Orn/Wht
Blu
Wht
16
16
16
905
977
978
Wiper Motor B+
To Wiper Switch/To Wiper
Motor
To Wiper Switch (Low)
Fuse Block
Wiper Motor
Wiper Motor
Wiper Switch
Coordination
Switch/Wiper
Motor
Wiper Switch
Park/Washer Coordination
Switch/Wiper
Motor
Wiper Switch
Blk 16 984 To Coordination Switch/To
Wiper Switch
Wiper Coordination Switch
Wht 16 980
Coordination
Switch
Wiper Switch
Coordination Coordination Switch
Motor/Wiper
Switch
Red 16 983 Washer
Blk 16 984 To Coordination Switch/To
Wiper Switch
Wiper
Motor/Wiper
Coordination Switch
Switch
Wiper Switch Coordination Switch
Blk 16 985 To Wiper Motor/To
Coordination Switch
Wiper Motor Coordination Switch
Blu 16 977
Wiper Motor
To Wiper Switch/To Wiper
Wht 16 979
Red 16 982
Motor
To Wiper Motor (Low)
Wiper
Wiper Switch
Wiper Switch
Switch/Wiper
Switch
Wiper Motor
Wiper Motor
Wiper Motor
Wiper Motor Blk
Grn/Red
Grn
16
14
14
985
917
918
To Wiper Motor/To
Coordination Switch
Brake Switch
Brake Switch B+
Brake Switch Output
Coordination
Switch
Fuse Block
Turn Signal
Switch
Dimmer Switch
Switch
Red/Blk 14 909 Dimmer Low Beams
Red/Ylw 14 907 Dimmer Switch B+ Headlight
Switch
Brake Switch
Brake Switch
Dimmer Switch
Dimmer Switch
Dimmer Switch
“Center Spade”
Table 8.2 Wire Connection Index
27
Wire
Starting
Point
UNDER DASH SECTION Con’t
Wire Ending
Point
Be sure to follow Figure 7-19 for Heater only and Figure 7-20 for Heater and A/C.
Blower Motor
Brn 14 967
Ylw 14 976
Blower Motor B+
Blower Motor/To Blower
Motor Resistor
Fuse Block
Blower
Motor
Resistor
Heat-A/C Blower Motor Resistor
Blower Motor
Blower Motor
Blk/Ylw 14 973 Blower Motor (High)
Blu
Red
Ylw
Blk/Ylw
Blu
14
14
14
14
14
974
975
976
973
974
Blower Motor (Med)
Blower Motor (Low)
To Blower Motor Resistor/To
Blower Motor
Blower Motor Switch
Blower Motor (High)
Blower Motor (Med)
Heat-A/C
Switch
Heat-A/C
Switch
Heat-A/C
Switch
Blower
Motor
Blower
Resistor
Block
Blower
Resistor
Block
Blower Motor
Resistor
Blower Motor
Resistor
Blower Motor
Resistor
Blower Motor
Resistor
Blower Motor
Switch
Blower Motor
Switch
Red 14 975 Blower Motor (Low)
Under-Dash Section Accessories
Blk/Wht 14 903
Blk/Red 18 930 Tachometer Light B+ Headlight
Switch
Red 18 966
Red/Ylw 18 923
Tachometer B+
Signal
Blower
Resistor
Block
Blower Motor
Switch
Tachometer Light
Fuse Block Tachometer Power
Engine
Section
Tachometer
Signal
Orn
Blk
Blu/Red
Red
Pur
16
18
18
18
18
991
992
930
940
968
Accessory Relay Power
Output (20 Amp Max)
Accessory Relay Activation
Ground
Radio Light B+
Constant Radio B+
Ylw/Blk 18 941 Switched
Table 8.2 Wire Connection Index
Brake Warning
Accessory
Relay
Accessory
Relay
20 Amp or less
Accessory
Ground Activation
Switch
Light in Radio Headlight
Switch
Fuse Block Radio
Fuse Block Radio
Brake Light Emergency Brake
Switch
28
Grn/Ylw
Blk/Blu
Blk/Blu
18
18
18
Wire
Starting
Point
INTERIOR LIGHTING SECTION
988
988
To Right Door Jamb Switch
B+
To Right Door Jamb Switch
Fuse Block
Interior
Lighting
Circuit
989 Right Courtesy Light Right Door
Jamb Switch
987 To Left Door Jamb Switch B+ Fuse Block
Wire Ending
Point
Right Door Jamb
Switch
Right Door Jamb
Switch
Right Courtesy Light
Grn/Ylw
Blk/Blu
Blk/Blu
18
18
18
987
989
To Left Door Jamb Switch
Left Courtesy Light
Interior
Lighting
Circuit
Left Door
Jamb Switch
Fuse Block
Left Door Jamb
Switch
Left Door Jamb
Switch
Left Courtesy Light
Grn/Ylw 18 990 To Glove Box B+
Blk/Blu 18 945
Blk/Red 18 956
Grn/Orn 14 949
REAR LIGHT SECTION
Orn/Blu 14 948 Right Turn Signal
Ylw/Wht 18 939
929
Blk
Grn/Ylw
18
18
962
946
Left Rear Turn Signal
Fuel Sending Unit
Lights
License Plate Light B+
Trunk Light B+
Headlight
Switch/Jamb
Switches
Dome Light
Back-Up
Light Switch
Turn Signal
Switch
Turn Signal
Switch
Back-Up Lights
Left Rear Turn/Stop
Signal
Right Rear
Turn/Stop Signal
Fuel Gauge Fuel Sending Unit
Headlight Tail Lights
Switch
Headlight
Switch
Headlight
Switch
License Plate Light
Trunk Light
Table 8.2 Wire Connection Index
Headlight
Switch
Glove Box Light
Switch
Center Console
Light
29
Painless Performance Limited Warranty
and Return Policy
Chassis harnesses, fuel injection harnesses, and Striker ColdShot units are covered under a lifetime warranty.
All other products manufactured and/or sold by Painless Performance are warranted to the original purchaser to be free from defects in material and workmanship under normal use. Painless Performance will repair or replace defective products without charge during the first 12 months from the purchase date. No products will be considered for warranty without a copy of the purchase receipt showing the sellers name, address and date of purchase. You must return the product to the dealer you purchased it from to initiate warranty procedures.
30

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Key features
- Complete wiring system
- Easy installation
- Color-coded wires
- Pre-installed fuses and relays
- Anti-theft feature
- Includes all necessary terminals