Purchasing replacement electrical connectors?

Hi Folks,

I had a few electrical connectors melt on my 2000 Jeep TJ.
Specifically, the headlamp dimmer and A/C control connectors. Does
anyone know if you can purchase these separate instead of the WHOLE
wiring harness? Also any tools that might be involed to crimp the
wires into the connector?

Thanks,
Nick

The 'Help' line of products that some stores carry have some, otherwise
it can be junk yard time or individual pin time.

I just individually put a connector on each wire and plug it in
according to the colour code. When I do this, I leave about a half inch
on the burned plug when I cut it off so I know what colour goes where.

Auto parts stores sell plugs and the crimp connectors for them. They
are not expensive. They can be different sized than electronic store
plugs though, so I recommend you shop at the auto store. The auto store
also have double walled heat shrink that comes with a heat activated
waterproofing goop inside and some crimp spade or bullet connectors
built like that. You crimp them on, then heat them and the goop seals as
the heat shrink shrinks. That works well.

The old pins can be pulled out of the plug by using a mini screwdriver
down the back side to push in a tab that releases them. You then can
heat shrink the good ones and just change the one burned one if that is
the case.

Mike
86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
88 Cherokee 235 BFG AT's
Canadian Off Road Trips Photos: Non members can still view!
Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
(More Off Road album links at bottom of the view page)

Nick Hughes wrote:
>
> Hi Folks,
>
> I had a few electrical connectors melt on my 2000 Jeep TJ.
> Specifically, the headlamp dimmer and A/C control connectors. Does
> anyone know if you can purchase these separate instead of the WHOLE
> wiring harness? Also any tools that might be involed to crimp the
> wires into the connector?
>
> Thanks,
> Nick

Nick Hughes wrote:
> Hi Folks,
>
> I had a few electrical connectors melt on my 2000 Jeep TJ.
> Specifically, the headlamp dimmer and A/C control connectors. Does
> anyone know if you can purchase these separate instead of the WHOLE
> wiring harness? Also any tools that might be involed to crimp the
> wires into the connector?

Ask the parts counter about a pigtail. They like to be lazy and order
entire harnesses when they should be ordering just the pigtail.

I've found these folks helpfull in the past.
http://www.chryslerpartsdirect.com/
They have a 1-800 number and some of the sharpest parts folks
I've ever dealt with.

--
DougW

Hi Nick,
You'll probably have to go to a bone yard to avoid buying the whole
harness. the plug socket wires are held in their plugs by little barbs,
you may release and change out via a small screw driver slid down inside
to release it: http://www.billhughes.com/temp/plugWireRelease.jpg while
you there you might rip the switch too at it's usually cooked too.
God Bless America, Bill O|||||||O


Nick Hughes wrote:
>
> Hi Folks,
>
> I had a few electrical connectors melt on my 2000 Jeep TJ.
> Specifically, the headlamp dimmer and A/C control connectors. Does
> anyone know if you can purchase these separate instead of the WHOLE
> wiring harness? Also any tools that might be involed to crimp the
> wires into the connector?
>
> Thanks,
> Nick

Mike Romain wrote:
> I just individually put a connector on each wire and plug it in
> according to the colour code. When I do this, I leave about a half inch
> on the burned plug when I cut it off so I know what colour goes where.
>

I was considering this, but wanted a "drop in" modular replacement
policy, for the next time a part breaks. Also, I was considering
using molex style connectors like you mention, however they would have
to be later attached to the replacement part.

If the harness or connecter prices are not reasonable, I'll probably do
the above. Maybe solder an intermediate molex style connector between.

Thanks

I had a similar problem.
I went to the dealer parts guy and he had a whole box of different
connectors ,we were able to match them up.
Parts guy said this is how they did there connector replacements.
"Nick Hughes" > wrote in message
oups.com...
> Hi Folks,
>
> I had a few electrical connectors melt on my 2000 Jeep TJ.
> Specifically, the headlamp dimmer and A/C control connectors. Does
> anyone know if you can purchase these separate instead of the WHOLE
> wiring harness? Also any tools that might be involed to crimp the
> wires into the connector?
>
> Thanks,
> Nick
>

DanFXR wrote:
> I had a similar problem.
> I went to the dealer parts guy and he had a whole box of different
> connectors ,we were able to match them up.
> Parts guy said this is how they did there connector replacements.

Thanks. I went today to the Chrysler parts counter. He looked through
the computer and couldn't find the replacement connector or harness.
Also, I looked through the Chysler connector book he provided. No
luck.

I'm wondering if I should just cut the melted connector and bring it
in?

DanFXR wrote:
> I had a similar problem.
> I went to the dealer parts guy and he had a whole box of different
> connectors ,we were able to match them up.
> Parts guy said this is how they did there connector replacements.

Dan,

Do you happen to have the receipt? If so, we can maybe obtain the part
number. This would really help as the dealerships here in
Massachusetts don't seem to dig through bins without part numbers.

Thanks

I went to another dealership and they still couldn't find the
connector. I finally gave up my search and made my own custom
connector. I used Anderson Powerpole connectors for the Blower Feed
and High speed circuits. These are 12 gauge wires carrying much
current. For the other 16 gauge wires, I used a trailer wiring harness
connector.

Short leads (about 5") were soldered to the AC Heater Control unit and
connectors. The stripped wire was loaded with solder, then the actual
pin on the AC Heater Control unit was also loaded with solder. When
complete, I soldered/joined the wire to the units pins taking care not
to melt the plastic.

The 5 pin fan speed connector was eventually filled with epoxy around
the pins. This should prevent any water or other material from
accidently grounding them. I wrapped tape around the 5 pin switch
connector to make a mold, then simply filled in 10 min epoxy.

Also note, you don't have to replace the entire AC Heater Control unit
if your fan speed switch melts! The fan speed switch and 5 pins unbolt
from the unit. The replacement is part number 1-05011214AA (2000 Jeep
TJ), and is about $20.

Another problem I encountered was the blow motor resistor again. Only
the high speed would work for me. When taking it apart, it looked in
great shape (no rust new looking), however there was no continuity
between the input pins. Maybe the diode was blown? Anyway, I had to
order a new one, which ran ~$45.

Thanks DaimlerChrysler!

Hope this helps someone in the future.

Nick


DanFXR wrote:
> I had a similar problem.
> I went to the dealer parts guy and he had a whole box of different
> connectors ,we were able to match them up.
> Parts guy said this is how they did there connector replacements.
> "Nick Hughes" > wrote in message
> oups.com...
> > Hi Folks,
> >
> > I had a few electrical connectors melt on my 2000 Jeep TJ.
> > Specifically, the headlamp dimmer and A/C control connectors. Does
> > anyone know if you can purchase these separate instead of the WHOLE
> > wiring harness? Also any tools that might be involed to crimp the
> > wires into the connector?
> >
> > Thanks,
> > Nick
> >

Nick Hughes wrote:
> I went to another dealership and they still couldn't find the
> connector. I finally gave up my search and made my own custom
> connector. I used Anderson Powerpole connectors for the Blower Feed
> and High speed circuits. These are 12 gauge wires carrying much
> current. For the other 16 gauge wires, I used a trailer wiring harness
> connector.
>
> Short leads (about 5") were soldered to the AC Heater Control unit and
> connectors. The stripped wire was loaded with solder, then the actual
> pin on the AC Heater Control unit was also loaded with solder. When
> complete, I soldered/joined the wire to the units pins taking care not
> to melt the plastic.
>
> The 5 pin fan speed connector was eventually filled with epoxy around
> the pins. This should prevent any water or other material from
> accidently grounding them. I wrapped tape around the 5 pin switch
> connector to make a mold, then simply filled in 10 min epoxy.

Just a note he Water is much maligned and feared but is actually a
****-poor conductor of electricity, especially at the voltage levels
present in automobiles. One is much more likely to have problem with
corrosion following exposure to water than for the water to actively
short circuit power to ground (if it did, it would quickly heat up and
vaporize, eliminating the problem). Corrosion on the other hand causes
resistance, resistance causes heat, heat melts plastic and causes fires.

It is different in electronics where your are dealing with tiny effects,
or in high voltage where you have a better chance of generating an arc,
but in low-voltage general power-carrying circuits water isn't an
immediate problem.



--

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