How-To: disassembling Plug/ add or remove single wires

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Gnuserup
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How-To: disassembling Plug/ add or remove single wires

Post by Gnuserup » Mon Sep 06, 2010 4:13 am

Pay careful attention to the condition of your plug as the older plastic might easily break as it could be brittle.

Disconnect the batterie to avoid a short.

You can add a wire without disassembling the plug. Just put the cable shoe into the plug until you hear a click and the cable is fixed so that you cant pull it out anymore.

To remove a wire you should carefully disassemble the plug so that you can release a little plastic hook that holds the cable shoe and pull it out.

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Gnuserup
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PCM-Plug on ngc-Neons

Post by Gnuserup » Wed Feb 16, 2011 3:54 pm

Because the black PCM-plug has been damaged by the accident on my SXT I had to care about fixing it.
Thanks a lot Mike for sending me that thing !

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So let´s get started...:

On the picture above you can see the red clip and the black barb
which are holding the cableshoes right in place, move the red clip to release one of them

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remove the lid

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and the grey seal


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Now the second barb - it´s more difficult. Either try a needle from the bottom of the plug

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or a very tiny screwdriver from the back

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or both and carefully get the cableshoe out.

The lid has a couple of little plastic nibs to prevent using the wrong
slot. So if you like to install a new wire you have to break the needed out.

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This way you can add new wires for cruise control, ABS or something else you like.

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Post by OB » Wed Feb 16, 2011 4:00 pm

There are tools designed specifically for servicing terminals like this. I would recommend using the correct tools to prevent damage to the sensitive components. I have a kit made by Snap-On, but there are several others on the market as well.
-Derek

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Gnuserup
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Post by Gnuserup » Wed Feb 16, 2011 4:09 pm

Yeah, now, as you say it, I believe, there has to be a tool for that work.
Could you post some pictures and/ or part-number for the one you have ?

Apart from that it could succesfully be done if you are very careful.

occasional demons
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Post by occasional demons » Wed Feb 16, 2011 9:08 pm

Wiha tools might have something. May need to contact them. They would be more local to you than Snap on, I would think.

http://www.wihatools.com

These are very nice quality tools.

The FSM specifies:
Probing Tool Package 6807 for diagnostic probing. (Voltage testing)

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

Molex connectors require Tool 6742
Augat = 6932
Thomas And Betts = 6934

http://www.handsontools.com/Miller-Tool ... 35534.html

http://millerspecialtools.spx.com/Detai ... 247&gid=15

http://www.handsontools.com/Terminal-Tools_c_706.html

http://millerspecialtools.spx.com/Displ ... aspx?id=15
Bill
dblsg wrote:ya'll a bunch of post whores
epic

2001 Neon ES MTX with '02 R/T PCM
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Gnuserup
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Post by Gnuserup » Thu Feb 17, 2011 2:03 pm

nice tools - nices prices

I think for just one plug I´ll go on with my simple screwdriver :lol:

occasional demons
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Post by occasional demons » Thu Feb 17, 2011 3:15 pm

:D

A small pick, and jeweler's screwdriver set works fine for me too.
Bill
dblsg wrote:ya'll a bunch of post whores
epic

2001 Neon ES MTX with '02 R/T PCM
Help support 2GN!

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Gnuserup
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Post by Gnuserup » Wed Mar 16, 2011 4:11 am

Sure this thing works for the taillight-plugs, too. This is needed if you plan either to make a us-neon bux or reverse.
Have I already said, that I really don´t like to cut wires if not needed ? :laughing3:

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Hardest thing is to make that if it is warm enough around you so that the plastic isn´t too hard and sprittle, disassemble the plug
carefully and find the hooks that holds the cableshoes.

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If you once have released any needed wire you will be able to rewire it the way you like and avoid weak points (which you otherwise would have if you are cutting, soldering and isolating the wires).

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