Electrical Connector Repair

[QB93Z]

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]

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

[Jagdpanzer]

Great information Jim, thanks for sharing

[tomtom72]

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

[billybaloneey]

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]

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

[Pete]

Good job Jim.

For the Chicago boys here's a place in our back yard they will take care of you while you wait.
https://www.casperselectronics.com/s...contact_us.php

They'e in Mundelein,IL same town as Flatout Gaskets pick up some gaskets while there.


Pete

[billybaloneey]

Originally Posted by QB93Z

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.


Jim

Ah...mystery solved.