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Untangling Wiring Harness Mysteries
By Mark Ehlen, Photography by Courtesy Of MCR, Mark Ehlen
July 01, 2008
The missing terminal in this connector is for the amp gauge. Corrosion in a high-current connection will generate enough heat to melt the connector and wiring. This damage-especially to the plug-cannot be repaired, and since there will normally be damage to the other half of the bulkhead connector as well, it's best to replace it.
The missing terminal in this connector is for the amp gauge. Corrosion in a high-current c
Another common connector problem is broken retaining clips on the bulkhead plugs. This is normally caused by someone trying to improperly remove the connector. Over time, missing clips can lead to a loose connection, which can lead to overheating, and then a melted connector, and then . . . well, you get it.
Another common connector problem is broken retaining clips on the bulkhead plugs. This is
Wire insulation can get brittle over time, particularly under the hood. If your harness is this brittle, it's a good reason to simply replace the entire harness.
Wire insulation can get brittle over time, particularly under the hood. If your harness is
Many wiring problems are caused by what other owners have added in the past.
MCR finds all kinds of junk on old harnesses. Wire nuts and crimp on splice connectors should never be used for any reason.
MCR finds all kinds of junk on old harnesses. Wire nuts and crimp on splice connectors sho
They may be a quick fix, but they also invite corrosion and eventually will fail.
Maybe there is a way to repair a melted connector after all. Some "clever" owner drilled out the bad terminal slot, ran a heavy gauge wire through the hole, and wire nutted both ends. I guess you have to give him credit; it probably kept him on the road.
Maybe there is a way to repair a melted connector after all. Some "clever" owner drilled o
Sometimes there are problems that are caused by people who should know better. The gold terminal that you see here is connected to the green wire coming out of the back of the connector. It was likely added by a dealer or other repair shop to power some accessory, probably air conditioning.The problem is a GM terminal was used. While it fits in the terminal slot, its design is different enough that it breaks the plastic around the terminal when the other connector is plugged into it. It works, but now it must be replaced.
Sometimes there are problems that are caused by people who should know better. The gold te
Good dielectric grease is an absolute must when reassembling wire connectors. It seals out moisture and will protect the connections for many years to come.
Good dielectric grease is an absolute must when reassembling wire connectors. It seals ou
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By Mark Ehlen
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