Member Since: 06 May 2012
Location: Arizona
Posts: 48
Hack a harness plug?
Background: I smacked the rear bumper on an offroad trail a few months ago (deeper than expected puddle), and the reverse sensor stopped working. One of the bezels was cracked and the sensor had a few chips, so I assumed that was the problem and ordered replacements.
But when I finally got around to removing the rear bumper this past weekend to do the replacement, I found some other hidden damage. The wiring harness for a different sensor had been pulled completely off the sensor. Furthermore, one of the wires in the harness broke off where it inserts into the harness (see photos).
In the above image, you can see the broken wire where it inserts into the plug on the left-hand side
In the above, the broken wire is at bottom
Has anybody ever taken one of these harness plugs apart to insert a small length of wire to replace the broken one? I’d like to do this and then splice it back into the complete harness for the rear sensors.
I searched for parts, and it seems that I’d have to buy the entire wire harness for all the rear sensors. I.e., you can’t buy just a single harness plug with a short length of wires to splice in to the mother harness.
1st Feb 2018 1:54 am
carbore
Member Since: 06 Apr 2016
Location: Cornwall
Posts: 545
Not done one, but I have done a lot of tinkering.
Id say.
A: Clean it of an Have a really really good luck at the plug, look for any numbers at all thing might be part/mfr numbers etc and then hit google hard including images searches to see if you can find a new one. Include land rover or ford in the query (and then not) basically keep trying.
B:Yoy might be able to push the pin out, open the crimp and re crimp/solder. Pins are not really meant to come out as they typically push/expand, but sometimes you can bend flanges back with screwdrivers enough to pop them out form the other side. Its unlikely to ever be good as new.
c: Look/ask-for a part loom from a vehicle dismantler
D: If you have soldering iron, see if you can get a decent fix to solder the wire back on. May well be tricky as the metal end plug will suck up a lot of the heat, so you need some good skill/luck to get it right.Disco 3: Lotus Elise S1: Ferguson T20: Audi A2
3rd Feb 2018 12:47 pm
carbore
Member Since: 06 Apr 2016
Location: Cornwall
Posts: 545
Member Since: 06 Nov 2004
Location: Hook Norton
Posts: 18495
You should be able to unlock the connector (green slider) then use a paperclip or very small flat-blade screwdriver to push down the barb on the terminal with the broken wire, and extract it (pull very gently on the broken wire strands with needle nose pliers).
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