I'm not sure I understand what exactly you are saying here, but I'll try:
Another quick question, my cab harness is from a 78, but my cab is an 87. The 78 harness was a heat only truck, but the 87 cab is an A/C truck. The HVAC harness plugs into the cab harness separately, but the two dont appear to work together. The plugs are different. Any idea on what to do here? I have a feeling I'll be busting diagrams and a test light out for this one.
Is the 87 HVAC (A/C setup) harness still installed? If so - and all the engine side components are still there - don't worry. Wiring the 87 HVAC harness into the truck's main electrical harness and connecting it to the engine side components will be easy.
There are only two leads in that A/C harness that need to be connected to the main electrical system.
One lead (brown) comes from the fuse block and connects to the pigtail on back of the control assembly. This feed is used for the
control side (i.e. speed control) of the blower circuit and also compressor clutch activation.
The other external connection for an A/C equipped truck is the big red wire in the engine compartment. It connects to the firewall junction block and is the power supply to the blower. It is lead to the blower through the blower relay.
These wiring diagrams attempt to explain how fan speed is controlled:
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If the cab is set up for A/C (and you intend to use it) you will need an A/C specific harness. There are significant differences between the two years in the layout of the engine side of the systems - both in physical locations and type/number of control devices. These dwgs will give you an idea:
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But, other than that brown lead from the fuse block and the red lead to the JB, the AC harness is entirely segregated from the rest of the electrical system.
You will of course need a late model HVAC control panel, but that should still be mounted in the dash - correct?
On this part I don't follow you at all:
The HVAC harness plugs into the cab harness separately, but the two dont appear to work together. The plugs are different.
Are you talking about the style of connector used to connect the brown wire from the fuse block to the pig tail on the control panel? Like this?
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Those connectors are a pain to make up. If the two halves don't match up you will have to use solderless connectors.