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ampwire.jpg | Hits: 616 | Posted on: 12/28/21
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Amp Wire Routing for '80-96 Broncos & F-series (& '97 >8500GVWR)
IF THE IMAGE IS TOO SMALL, click it.
This job seems to be more difficult for many people than it should be. I've seen a wide variety of attempts at it - most of which are fire hazards. In this truck, there was a ~5/16" hole drilled through the firewall below the HVAC box and a nylon bushing inserted forward of the black firewall insulation pad above the passenger footwell. Then the wire ran under the carpet to the conduit under the threshold, and out of the seat belt reel cover across the cargo floor to the sub box where the amp was attached. It worked, but it was subject to wear under the carpet, and being pinched in a wreck. So I plugged that hole and re-routed the cable better, mostly along Ford's harness sections.
1) A long Phillips screwdriver is a good way to puncture the rubber grommet with very little risk of damaging anything else (especially wires). This one is much longer than necessary, but it's easier to show. A bit of silicone grease on the tip makes it easier to puncture the molded rubber.
2) & 3) Inserted in this direction, the screwdriver is aimed at the large recirculate hole in the firewall where the factory wiring passes through.
4) I temporarily crimped the end of the wire into this short piece of flexible Copper tubing which I'm using like a needle pulling thread.
5) After the wire began through the grommet, I added some soapy water to the grommet's well to make pulling the wire easier.
6) It's easy then to follow the factory wiring path, occasionally wrapping the cable so it stays put. I pulled it up through the B-pillar like the factory rear speaker wires and across the RHR wheelwell. I may add a terminal block later to make it easier to connect several accessories like an amp, inverter, or anything else that won't overload the wire.
7) The wire is routed through the fender to keep it away from the hood prop and tire-changing tools. It's also a good place to keep the fuse holder from being damaged.
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