Electrical Connector Repair - ZR-1 Net Registry Forums

QB93Z · 06-24-2009

On my 1990 ZR-1, the oil pressure gauge indicated pegged-high. I looked at the oil pressure sensor and found that the electrical connector was secured with tape. I pushed it in and the oil pressure gauge indicates properly. When I looked at the connector, I found that the clip was broken off. This is a problem that happens a lot on our cars.

I searched for a way to repair or replace the connector. I found a good source to solve this problem:

http://www.repairconnector.com/

Many of the WeatherPack connectors on the LT5 are available on their website, and they sell the tools to replace the connectors.

The connector I bought came with wire pigtails installed and butt splices. The repair can be done by cutting off the old connector and then crimp-splicing the new connector to the wire harness.

But there is a better way.

Here is the oil pressure sensor after I repalced the connector:

Here is how it works:

The tool is used to remove the wires from the connector by pushing it into the face of the connector (This picture is on my bench, the same procedure is used on the engine):

Then the wire on the engine harness can be pushed into the back of the new connector, and the black wire retainer is replaced to secure the wires.

jonszr1 · 06-24-2009

wow thanx for the info .i have a lot that need replacing

Jagdpanzer · 06-24-2009

Great information Jim, thanks for sharing

tomtom72 · 06-25-2009

Yea Jim, thanks for sharing this info.....

billybaloneey · 06-25-2009

Your picture, (the first one), on the connector installed on the sensor, it shows a light brown wire coming out of the back of the connector, your how-to picture, (the second one), shows a black wire. Did you have to replace the whole length of wire in the harness to the sensor? I don't have mine memorized, so I don't know if there are one or two wires...a black one and a light brown one), on that sensor/connector.

A lot of people must have just recently visited & bought the connector pin push tool set...the link to the vendors web site said they only had 1 set left in stock.

Thanks for the How-To tip.

QB93Z · 06-25-2009

I did the repair and then decided to post the info. So, I had to recreate some of the scenes. (Some of the names have been changed to protect the innocent)

Bottom line, The light brown wire from the harness to the oil pressure sensor is the original wire. The black wires shown in the bench picture came mounted in the new connector. I removed the black wires from the new connector and I removed the light brown wire from the broken connector. Then I inserted the light brown original wire into the new connector.

Note: this is a three wire connector and the system only uses one wire, so there a two hole-filler plugs to keep moisture out of the connection. You can see the orange tip of one of the hole fillers in the LT5 picture.

Jim

06-24-2009	#1
QB93Z Join Date: May 2007 Location: Westminster, Maryland Posts: 3,689	Electrical Connector Repair On my 1990 ZR-1, the oil pressure gauge indicated pegged-high. I looked at the oil pressure sensor and found that the electrical connector was secured with tape. I pushed it in and the oil pressure gauge indicates properly. When I looked at the connector, I found that the clip was broken off. This is a problem that happens a lot on our cars. I searched for a way to repair or replace the connector. I found a good source to solve this problem: http://www.repairconnector.com/ Many of the WeatherPack connectors on the LT5 are available on their website, and they sell the tools to replace the connectors. The connector I bought came with wire pigtails installed and butt splices. The repair can be done by cutting off the old connector and then crimp-splicing the new connector to the wire harness. But there is a better way. Here is the oil pressure sensor after I repalced the connector: Here is how it works: The tool is used to remove the wires from the connector by pushing it into the face of the connector (This picture is on my bench, the same procedure is used on the engine): Then the wire on the engine harness can be pushed into the back of the new connector, and the black wire retainer is replaced to secure the wires. __________________ If it isn't fun, you aren't doing it right! 1990 Black ZR-1 - sold 1993 Quasar Blue ZR-1 1994 Competition Yellow ZR-1 1995 Dark Purple ZR-1 Maryland State Coordinator WAZOO Member

06-24-2009	#2
jonszr1 Join Date: Sep 2006 Location: lone pine and mammoth lakes Posts: 1,407	Re: Electrical Connector Repair wow thanx for the info .i have a lot that need replacing

06-24-2009	#3
Jagdpanzer Join Date: Apr 2007 Location: Northern VA Posts: 2,661	Re: Electrical Connector Repair Great information Jim, thanks for sharing

06-25-2009	#4
tomtom72 Join Date: Dec 2004 Location: Jacksonville, FL USA Posts: 4,645	Re: Electrical Connector Repair Yea Jim, thanks for sharing this info..... __________________ 1990 ZR-1, Black/grey, #2233, stock. ZR-1 Net Reg Founding Member #316 & NCM member

06-25-2009	#5
billybaloneey Join Date: May 2008 Location: Mauriceville, Texas Posts: 179	Re: Electrical Connector Repair Your picture, (the first one), on the connector installed on the sensor, it shows a light brown wire coming out of the back of the connector, your how-to picture, (the second one), shows a black wire. Did you have to replace the whole length of wire in the harness to the sensor? I don't have mine memorized, so I don't know if there are one or two wires...a black one and a light brown one), on that sensor/connector. A lot of people must have just recently visited & bought the connector pin push tool set...the link to the vendors web site said they only had 1 set left in stock. Thanks for the How-To tip. __________________ Clint aka billybaloneey '94 - C4 ZR-1 #445 - Black/Black '05 - C6 silver/black 6sp '85 - C4 white/graphite (almost done) automatic '78 - C3 silver/black (a work in progress) automatic

06-25-2009	#6
QB93Z Join Date: May 2007 Location: Westminster, Maryland Posts: 3,689	Re: Electrical Connector Repair I did the repair and then decided to post the info. So, I had to recreate some of the scenes. (Some of the names have been changed to protect the innocent) Bottom line, The light brown wire from the harness to the oil pressure sensor is the original wire. The black wires shown in the bench picture came mounted in the new connector. I removed the black wires from the new connector and I removed the light brown wire from the broken connector. Then I inserted the light brown original wire into the new connector. Note: this is a three wire connector and the system only uses one wire, so there a two hole-filler plugs to keep moisture out of the connection. You can see the orange tip of one of the hole fillers in the LT5 picture. Jim Last edited by QB93Z; 06-25-2009 at 01:34 PM.