Multi-pin Electrical Connector

[jhorton3]

What's the best way to remove wires from a multi-pin electrical connector and put them in a new connector? Is there a special crimp tool needed? I need to replace the connector where the ignition switch plugs into the wiring harness under the dash. My original switch was a 5 port connector. I currently have a 7 port connector switch I modified, but it's not holding together anymore.

 

[bill_young]

Jim, most electrical connectors use special tools to release the retaining clips on the pins for removal. I don't know what type of tool you would need, but you might try contacting British Wiring and see what they advise. The other alternative would be to take a sample connector to a local electronics supply store and see if they could identify a tool that would work. I've used tiny screw drivers or even made tools up from brass tubing in a pinch. You might try to find a piced of thin wall brass tubing that will just slip over the pin and then find a solid piece that will slip inside. You push the outer section into the end of the connector to release the clips and then push the pin out with the inner rod. There us usually a special crimp tool needed as well and these aren't cheap, but really are almost necessary to get a good connection that will reinsert well into the connector housing. Using the wrong crimp tool may spread the contact too much to insert into the housing. Good luck.

 

[Hairyone]

Yep Bills right. Electrics is what I do. To remove contacts there will be a tine (spike) probably punched out in the terminal, though it could be in the housing. Take a reel good look down inside the housing. A suitable extraction tool can normally be made from a broken hacksaw blade. Grind the end down to about 1/16" wide 3/4" long & put a chamfer on the end. When you've found the latch the crimp will come out easily.
Don't be tempted to yoink it.

If you can't get them out cut the wires 2" behind the housing & solder them to your new wires, then sleeve well.
Most electrical faults on older cars are bad crimps or rusty earths.

 

[JPSmit]

you can also buy pin connectors with tails if that is easier

 

[jhorton3]

It sounds like I've got more work ahead of me than I thought with this project, but I have to do it to make it safe and reliable.

 

[JPSmit]

Of course if it were completely safe and reliable you wouldn't need to come here

 

[Sarastro]

Let's see...Spridget...safe...reliable....

This sounds like one of those tests in school, where you have to pick out the word that doesn't go with the others.

 

[JPSmit]

Oooo Oooo I know - pick me

the answer is "Spridget" ! :lol:

 

[jlaird]

Drove one to work and back daily for almost 20 years. Never failed. Wife used one for a family car in the early days, never failed.

Bugeye, safe, reliable, fun.

 

[jhorton3]

I just don't want to let all the smoke out of the wiring harness. My windshield is foggy enough as it is.