Routing the new chassis loom
I have always believed that the best place for a Land Rover chassis loom is within the chassis rail. This is how they were built in the factory and it’s the way I have always routed them when I fit a new chassis to a Defender. Admittedly, it is much easier to attach the loom to the rail but, with an inexpensive drain clearing tool, a length of rope and some insulating tape, the loom can be routed through the chassis rail fairly quickly.
A correctly manufactured Land Rover chassis has anti-crush tubes within the chassis rails at numerous points where components are bolted to the chassis. Examples of this are where the gearbox crossmember is fitted, and at the location of the rear top damper (shock absorber) bracket. These internal anti-crush tubes can restrict the passage of the loom, depending on the exact route. For this reason, I started using a large nut tied along the rope (though this latest tool has a larger leading hook that essentially does the same job). If the nut or the leading hook fits through the chassis, then you know the route is correct for the chassis loom to pass through without becoming lodged under the crush tubes.
Repurposed tool 5
This flexible drain clearing tool has been my trusty chassis loom assistant for countless Defenders, having pulled many wiring harnesses through new chassis rails.
Front to back 6
The flexible drain cleaner tool spring-shaped end is inserted into the right hand chassis rail at the front hole, and jiggled through to the rear of the chassis.
At the end of the tunnel 7
The head of the tool emerges near the rear crossmember, and can be led to the outside or inside of the chassis rail, depending on how you wish to route your loom.
Check for restriction 8
This rope is taped to the tool and pulled through. The large nut (arrowed) will confirm it is not routed under one of the anti- crush reinforcement tubes.
Shining harness 9
The brand new chassis loom will replace the destroyed original loom and will be very much safer when properly routed through the chassis rail.
Ease it through slowly 10
The new loom has been taped to the rope and must be carefully fed into the chassis rail, while it is pulled through by the rope.
Unwrap and connect 11
The cables have pulled through safely and are ready to connect. The rope and attached nut are pulled back and out of the chassis.
Secure it, seal it 12
The new loom has chassis grommets that seal the holes and protect it, but the loom must also be properly secured to the chassis and bodywork at each end.