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1996 Ford F-250 Crew Cab

InfinityBox Wiring Build Manual

Table of Contents

Section Description Page
1 Master Wiring Reference 3
2 Supply Shopping Checklist 6
3 Tool Reference 9
Appendix A Color Coding Guide 11
Appendix B Harness Layout Tips 12
Appendix C Best Practices 13
Appendix D Subsystem Wiring Schematics 14
Appendix E Connector Reference 25
Appendix F Fusing Guidelines 28
Appendix G Grounding Strategy 30
Appendix H Testing Checklist 32
Appendix I Maintenance & Documentation 34

Section 1: Master Wiring Reference

Circuit AWG Type Color Length Qty Total
Battery → Mega fuse 4 SGX RED 3 ft 1 3 ft
Mega fuse → POWERCELL 8 SGX RED 8 ft 2 16 ft
Ground strap 4 SGX BLK 2 ft 1 2 ft

Section 2: Supply Shopping Checklist

  • Heat shrink tubing – 3:1 adhesive-lined (3M, Ancor)
  • Split loom tubing – high-temp nylon (Techflex, Panduit)
  • Cloth harness tape – Tesa 51036
  • Electrical tape – 3M Super 33+ or Super 88
  • Zip ties – UV-rated, metal locking tabs (HellermannTyton, Panduit)
  • Adel clamps – rubber-lined, various sizes
  • Firewall grommets – rubber, assorted sizes
  • Heat shrink labels – Panduit or Brady
  • Label maker – Brother P-Touch with heat-shrink cartridges

Section 3: Tool Reference

  • Crimpers:
  • Engineer PA-21 (22–10 AWG open barrel)
  • Rennsteig 624 series (Deutsch terminals)
  • Strippers:
  • Ideal Stripmaster Lite (22–10 AWG)
  • Klein 11063W (10–18 AWG)
  • Heat gun: Steinel HL1920E or Milwaukee variable temp
  • Multimeter: Fluke 115 or 117
  • Test light: Power Probe III
  • Labeler: Brother P-Touch PT-E550W

Appendix A: Color Coding Guide

Ford OEM color codes: - BK – Black (Ground) - RD – Red (Battery Feed) - YE – Yellow (Ignition Feed) - GN – Green (Accessory/Signal) - LB – Light Blue (Lighting Control) - WH – White (Communications/Diagnostics) - BR – Brown (Marker/Running Lights)

Appendix B: Harness Layout Tips

  • Route along factory channels where possible.
  • Use Adel clamps every 12–18".
  • Avoid sharp edges – always use grommets.
  • Separate power and signal runs where possible.

Appendix C: Best Practices

  • Always use adhesive-lined heat shrink on splices.
  • Label every run at both ends.
  • Avoid unnecessary splices – use junction blocks.
  • Service loops for flexibility.

Appendix D: Subsystem Wiring Schematics

Symbol Legend

  ▭ = Connector (C###)
  ● = Splice (S###)
  ⏚ = Ground (G###)
  ⇥ = Fuse/Breaker
  ◇ = Switch
  ⌂ = Lamp
  ⊗ = Motor
  ⬜ = Module/Box

D.1 Power Distribution

  ▭ Battery C100 ─── ⇥ Mega Fuse ─── ● S101 ─── ⬜ Front POWERCELL C105
                                        │
                                        └──── ⬜ Rear POWERCELL C106

   ⏚ G101 (Frame Ground) ←──── Cab Strap C111
   ⏚ G102 (Cab Ground)   ←──── Cab Strap

Connector Pinouts

Connector Component Pin Function
C100 Battery Connector 1 B+ to Mega Fuse
C101 Alternator Output 1 Charge to Battery
C110 Chassis Ground – Frame Ground
C111 Cab Ground Strap – Cab-to-Frame Ground

D.2 Front Lighting & Horn

        ● S201 ────────┬──── ⌂ Headlamp LH C200
        │              └──── ⌂ Headlamp RH C201
        │
   ⬜ Front POWERCELL C105
        │
        └── ◇ Headlamp Switch C202
        │
        └── ▭ Horn Relay C203 ─── > Horn

Connector Pinouts

Connector Component Pin Function
C200 Headlamp LH 1 Low Beam +
C201 Headlamp RH 1 Low Beam +
C202 Headlamp Sw. 2 Switch Feed
C203 Horn Relay 87 Output to Horn

D.3 Rear Lighting & Fuel

   ⬜ Rear POWERCELL C106 ─── ● S301 ─── ⌂ Tail Lamp LH C300
                               │
                               └──── ⌂ Tail Lamp RH C301

   Reverse Feed ─────────────── ⌂ Backup Lamps C303
   Fuel Pump Feed ───────────── ⊗ Fuel Pump C302
   ⏚ G301 (Rear Frame)

Connector Pinouts

Connector Component Pin Function
C300 LH Tail Lamp 1 Brake/Turn +
C301 RH Tail Lamp 1 Brake/Turn +
C302 Fuel Pump Conn 2 Pump B+
C303 Backup Lamp 1 Reverse Feed

D.4 Interior / Dash

   ▭ Ignition Switch C400 ─── ● S401 ─── Dash Cluster C401 (Illumination)
                               │
                               └──── Switch Bank C402 → IOX Inputs

   ⏚ G401 (Dash Bracket)

Connector Pinouts

Connector Component Pin Function
C400 Ignition Switch 1 IGN Feed Out
C401 Dash Cluster 2 Illumination +
C402 Switch Bank 3 Input to IOX

D.5 HVAC & Wipers

   ⬜ Front POWERCELL C105 ─── ⇥ Fan Relay C501 ─── ⊗ Blower Motor C500

   ⬜ Front POWERCELL C105 ─── ◇ Wiper Switch C502 ─── ⊗ Wiper Motor
                                 │
                                 └── Park Switch Return

   ⏚ G501 (Firewall)

Connector Pinouts

Connector Component Pin Function
C500 Blower Motor 1 B+
C501 Fan Relay 30 B+ from Fuse
C502 Wiper Motor 3 Park Switch Return

D.6 Doors

   ⬜ Rear POWERCELL C106 ─── ● S601 ─── ⊗ Window Motor C600
                               │
                               └──── ⊗ Window Motor C601
                               └──── Door Lock Actuator C602
                               └──── Door Lock Actuator C603

   ⏚ G601 (Door Shells)

Connector Pinouts

Connector Component Pin Function
C600 Window Motor 1 Up +
C601 Window Motor 2 Down +
C602 Lock Actuator 1 Lock +
C603 Lock Actuator 2 Unlock +

D.7 Trailer (OEM Ford 7-Way)

   ⬜ Rear POWERCELL C106 ─── ▭ Trailer Socket C700

Pinout: | Pin | Color | Function | |-----|--------|--------------------| | 1 | White | Ground | | 2 | Brown | Tail/Marker | | 3 | Yellow | Left Turn/Brake | | 4 | Green | Right Turn/Brake | | 5 | Black | Reverse | | 6 | Blue | Electric Brake | | 7 | Red | 12V Charge |

Connector Pinouts

Connector Component Pin Function
C700 Trailer Socket 1 Ground
C700 Trailer Socket 2 Tail/Marker +
C700 Trailer Socket 3 Left Turn/Brake +
C700 Trailer Socket 4 Right Turn/Brake +
C700 Trailer Socket 5 Backup Lights +
C700 Trailer Socket 6 Electric Brake Feed
C700 Trailer Socket 7 12V Battery Charge

D.8 Network / Diagnostics

   ⬜ InfinityBox MASTERCELL C805 ─── ● S801 ─── CAN High/Low to ▭ OBD-II C800
                                          │
                                          └── CAN High/Low to POWERCELLs

OBD-II Port (C800) | Pin | Function | |-----|----------------| | 4 | Chassis Ground | | 6 | CAN High | | 14 | CAN Low | | 16 | B+ |

Connector Pinouts

Connector Component Pin Function
C800 OBD-II Port 4 Chassis Ground
C800 OBD-II Port 6 CAN High
C800 OBD-II Port 14 CAN Low
C800 OBD-II Port 16 Battery Power
C805 MASTERCELL – CAN Backbone

Appendix E: Connector Reference

Connector Location Pins Notes
C100 Battery Connector 1 B+ to Mega Fuse
C101 Alternator Output 1 Charge to Battery
C110 Chassis Ground - Frame Ground
C111 Cab Ground Strap - Cab-to-Frame Ground

Appendix F: Fusing Guidelines

  • Main battery fuse: 175A Mega Fuse
  • POWERCELL feeds: 60–100A MIDI Fuses
  • Lighting circuits: 15–20A MAXI Fuses
  • Auxiliary circuits: match load, size wire accordingly

Appendix G: Grounding Strategy

  • Frame ground straps every 4–6 ft
  • Battery → Frame → Cab → Engine block
  • Star grounding at main distribution point

Appendix H: Testing Checklist

  • Continuity test for all circuits
  • Voltage drop under load <0.5V
  • Ground resistance <0.2Ω
  • InfinityBox configuration verified
  • Labels and documentation up to date

Appendix I: Maintenance & Documentation

  • Inspect harness yearly for abrasion or corrosion
  • Check clamp integrity and zip tie tension
  • Verify fuses and relays per spec
  • Update diagrams with any changes