fuse block help needed

[N8inVT]

ok, so original reason i made this account was to figure out some electrical issues i was having, (just keep this in mind). last night we (a good mechanic friend who is helping me get through this) were working on replacing the cylinder that was leaking on the fuse block. once getting into the project it was clear to see the PO had worked on it before. After the old cylinder was removed, we noticed that one of the stationary bolts in the firewall was bent slightly, and the top bolt had come out, and was replaced with a regular bolt (not metric) that was obviously not stationary in the firewall (just a bolt pushed through the hole)  while pondering what to do here, he started wiping down some wires coming out of the fuse block, cleaning the area up a little, and then the magic started. He was wiping a red wire off and it literally fell out of the fuse block, (see pics) also note that this red wire was spliced with a butt connector with exposed wire. Then removed fuse panel to see that the PO had put a metal tip on the end of the red wire to keep it in place (but it looks like it melted through, or fuse panel was drilled out?) also note the black grease caked inside fuse panel. So now it seems like a new fuse panel is needed. Is there a site that sells this? another question, is the red wire that was spliced supposed to have an inline fuse? seems like it should....guessing thats the reason the red wire may have melted back through if the panel wasnt drilled out.The orange wire coming out of harness was done the same way, but didnt melt through, but its not done right. how do we go about fixing this mess? I appreciate all the help in the biggest way, thanks again. 

[Pete M]

I split the post off into it's own topic so more eyes will see it.  

 

I do hate POIs (previous owner issues). 

[N8inVT]

Very nice! Thanks my friend!

[ghetdjc320]

Should be red wire is battery source, orange with black is fuel pump feed. You can verify by referencing the bulkhead connector pinout found here: 

 

 

Disconnect the battery and clean out that connector thoroughly. You can replace the grease with dielectric grease found at auto parts and electrical supply stores. You can get new pins from various sources but I tend to get all my electrical parts from either Mouser electronics or Painless Wiring. The actual bulkhead connector is a standard GM part. Contact painless and they can help if you need new pins. Its the same bulkhead connector they use in many of their harnesses (you can reference part number 10111 which is for a YJ and uses the same connector). I believe there are a few posts on here (check the DIY section) about how to install a pin back into the bulkhead connector. You will need a new pin and a way to crimp it to the wire. 

 

As for the clutch master cylinder hardware, the lower mounting point is a stud that is attached to the clutch pedal assembly that goes through the firewall. The upper is a bolt that goes into a threaded insert but you could just use a bolt and nut for the upper mount.