How to Fix Your Wire Harness Plug Connector
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One of the many behind-the-scenes parts of a vehicle, the wire harness plug and connector play a crucial role in your car’s overall functionality. Its cable assembly can be bombarded and worn down by harmful things like abrasion, moisture, extreme temperatures, and dust. All of these can damage components over time and cause the wires and plug to stop working. How can you fix your wire harness plug connector if it’s not operating?
There are two key components: the plug connector and the electrical wires that are connected. The name for this part is about as literal as it can get, and it can be a good idea to replace all components together at the same time. Like lots of people do when changing out their tires for consistency, replacing the wires and actual plug connector together can be a smart thing to do.
What is a wire harness plug connector?
A wire harness is essentially a small and organized network of wires, terminals, and the connector runs throughout the vehicle and relays information and electric power, playing a crucial part in connecting various components. Like the circulatory and central nervous systems in the human body, power and information move through the car thanks to this network. As part of this system, wire harness plug connectors serve as a link to ensure a constant flow of data, signal, and power so your car communicates and works properly.
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As cars continue to get more sophisticated, the key and main component parts become more reliant on electronics to conserve space and keep the vehicle functioning. Wire harnesses are a huge factor in improving the design and functionality of vehicles for the future. These can of course be super complex, but ultimately if the plug is faulty your car is at risk of not functioning properly.
Like plugs, chargers, and other tools, there is a male and female connector for the two most common types of wire harness plug connectors. The wire harness plug connectors help to link the many various parts of the wire harness to ensure that data, signal, and power are sent efficiently throughout the system. Plugs are male wire harness connections, while jacks are female wire harness connectors, to put it simply.
Electrical connections and wiring harnesses can sometimes burn out or melt, necessitating their replacement. On the actual plug connector, damage is more likely to come from external environmental damage and can essentially be swapped for a replacement. Fortunately, this is a rather straightforward fix and the technique to fix one is generally applicable to any in the vehicle.
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How to fix your wire harness plug connector (DIY)
Since the wire harness plug connector plays such a crucial role in functionality, it’s necessary to replace the plug connector if it’s faulty. If an electrical connector were to melt or burn, your car may be at risk of overheating and could start a fire. You can buy a connector set online and your local chain store for around $15-$25; you’ll just need to make sure the plug you’re replacing is included since each one can vary a bit. The process is pretty painless, and the first pre-step will be separating the actual connector from the wiring.
1. Separate the plug connector
Pretty simple, but when you’re replacing them you’ll want to begin by actually separating the two-piece wire harness plug connector. The connector assembly parts are held together by a small bracket, and you can release them by pressing the small button on top and pulling them away.
2. Remove the pins
Remove the front lock that holds the pins in place and remove the “catches” gently. It’s a fairly simple concept, but you just gently lift the lid with a small picking tool and you’ll be able to actually see the catch and pins.
With a pick or small screwdriver, you’ll then want to lift the catch (just slightly) and pull the pin out from the other side while the catch is still up. It’s important to pull the pin with the catch up otherwise it could get stuck and potentially damaged, and ruin your new plug connector. There should be somewhere between 2 and 12 total pins in the connector, and once they’re all removed you can add the new replacement wiring.
3. Replace the wires (or inspect them)
A fairly high amount of issues with fixing your wire harness plug connectors will come from the wires themselves. This can get a bit pricier and can run over $100, so getting a professional opinion or consultation to ensure you get the right equipment (and install correctly).
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How to fix your wire harness plug connector (the wires)
- Remove the wiring from the loom and inspect it for damage. Check for any signs of burning, melting, or ripping in the wire. This is where significant damage can come from and create a hazard for the rest of the vehicle. If you see anything that even could be damage, it’s best to replace it to be safe.
- Make that the new and old electrical connectors are the same. There’s a good chance the color of the new wire won’t match the original unless the replacement comes from the same manufacturer. A good trick is to cut one side of the cable just a bit shorter than the other to distinguish the two, and to do the same while removing the previous wiring harness.
- Once they’re placed you’ll want to strip wire ends and twist them tightly. With an insulated weatherproof connection, crimp each wire on the electrical connector. You should be able to gently pull on the wire without completely removing it from the plug connector.
- Lastly you’ll want to secure the wire to the connector. You can do this with either a lighter (more secured but easier to damage) or with electrical tape. The electrical tape should work effectively, but not quite as well as securely melting it.
While it’s an incredibly important component for your vehicle’s overall functionality, it’s also fairly simple. You’ll need a minimal amount of equipment, time, and money to fix your wire harness plug connector - although some outside help is always worth considering if you’re worried about fixing it properly or just want some expert help.
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