Wiring Harness Connector Pin Repair

Now that my engine bottom end was about done I turned my gaze to the heads. They needed some work that I could not do myself so I dropped them to a machinist that would inspect them. This would take a week or two so I had some time to do other stuff with the car.

When I was preparing the engine bay for painting, I removed the wiring harnesses. Unfortunately one pin in the main connector broke when taking it out. I checked a wiring diagram and it was the main power wire from the engine bay to the cabin. This is quite logical as it carried the most current so it would also corrode fast.

I did some Googling and found others that had the same problem. The discussion had some good instructions on how to fix the broken pin so decided to try it. I began be drilling a hole to the connector so I could screw in a new pin.

I had a small hook that had threads in it. I screwed it in the hole.

To make sure the pin had good contact with the wire in the connector, I melted some solder on it. I was not worried about the neatness at this point as I would have to add some more to solder the stud on the pin.

I used a small Dremel like rotary tool to cut the hook.

For the stud I cut the head from a bullet type connector.

The stud slid nicely over the pin and I added some more solder to keep it in and to ensure a good connection.

The repair felt pretty solid and should suffice for now. I might have to do more electrical work later but at least I should have electricity in the cabin again.