An upper plastic lock tab broke on my bulkhead connector on my 65 Coupe. I have the Lectric Limited repair kit and a few articles describing the repair. Any other tips are welcome.
Dave K.
Dave K.
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Re: Bulkhead connector repair
Everything you need to know:
https://www.corvetteforum.com/forums...onnectors.html
Take careful note of the pin removal tool in the first picture - you'll want that before starting. Take copious smartphone pics of the wire locations before starting and have a wiring diagram handy....the Doc Rebuild OOSOEZ schematics are excellent.
As I removed each pin I CAREFULLY lifted the small tabs on each Delphi connector to ensure they "locked in" when inserted into the new housing. Don't overdo it, just lift the tabs gently a small amount. You'll get some debate on what to pack the housing with after you're done. Some say dielectric grease others say some other goo. I used dielectric and no issues in the subsequent 6 years.Last edited by Frank D.; August 3, 2021, 02:51 PM. -
Re: Bulkhead connector repair
Frank,
Did you have to use any of the Delphi connector pins? If so, how did you remove the old one from the wire without cutting the wire?
Regards,
Dave KComment
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Re: Bulkhead connector repair
I used the identical procedure on a few short wires on our 63.
My back still hurts.
RichComment
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Re: Bulkhead connector repair
In fairness here is what another CF member did which appears to have worked, vis a vis, pin replacement:
https://www.corvetteforum.com/forums...-repair-2.html
You will note my skepticism in my posts in that thread, but its hard to argue with results that have lasted 1/2 decade.Comment
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Re: Bulkhead connector repair
Frank,
Does it take two people to remove the pins? One to insert the tool and the other to pull it out or is there enough room to do both yourself?
Regards,
Dave K.Comment
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Re: Bulkhead connector repair
You push the tool into the firewall side of the housing at the connector until seated and you feel it "hit bottom" holding it there while tugging on the wire on the back side of the bulkhead housing and if you've properly depressed the connector tab with the tool, the wire will almost fall out. Sometimes it helps to jiggle things a bit... Once you've done a couple you'll think, "...this is no big deal".
A one man job. Honestly, if you tried to get two people working in that area you better be VERY good pals.
Like most jobs on these cars, the anticipation is far worse than the actual work.
THE NUMBER ONE CONCERN is getting the right wire in the right hole in the housing; you can have 30 amps running through some of those wires and a miswiring could be a disaster. I rechecked the wiring each time after doing about 4 connectors.
Get one of the good Coleman LED headlamps and remove the front seat, you'll be just fine.Last edited by Frank D.; August 4, 2021, 07:21 AM.Comment
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Re: Bulkhead connector repair
Thanks to all.
Dave K. 33108Comment
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Re: Bulkhead connector repair
Several of the connectors are being stubborn and will not come out. I moved around these connectors and to the others. Do not want to damage a connector.Comment
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Re: Bulkhead connector repair
Sometimes you need to use another part of the tool IIRC, it has both thin and thick blades to enter the housing and depress the tab - sometimes even a round part of the tool can help. As you work the tool in "moving it around slightly and making sure its seated" push forward on the wire at the rear and then tug it rearward while jiggling it. Don't forget, its just a little metal tab hanging up on some plastic in the housing; you'll get it.Comment
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Re: Bulkhead connector repair
Frank,
Thanks for the tip. Will do.
Dave K.Comment
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Re: Bulkhead connector repair
The only way you can screw something up doing pin removal if you yank back on the wire and distort or tear off the tab - it would take a LOT of force....to wit, don't be afraid to get a little creative with the pin/tool.Comment
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Re: Bulkhead connector repair
This what I did:
https://www.forums.ncrs.org/showthre...811#post894811Comment
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Re: Bulkhead connector repair
Frank,
I badly damaged one pin. Will need to carefully remove and replace.
Dave K.Comment
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