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Recall I broke one of the injector connectors while replacing my oil cooler. Already waited a week for the new cooler to arrive. Then another week for the EGR delete kit. Putting it back together last Friday is when the connector broke. It was so tight, I bent one of the pins trying to connect the harness, although I couldn't see that in the tight confines of this #450, and it kept pushing the connector back into the engine. Then, the plastic broke as I tried to pull it back out over and over. Order a new one, pay for two-day deliver, it comes in three days today.
PITA to change out in this van, but I actually get it done without removing the injector. Discover the bent pin in the process and try to straighten it out with some needle nose.
Get it back together and try to push the harness on, but the same pin bends again. Try to squeeze it straight again with the needle nose...you know where this is going, right?
Pin breaks off. Now, I'm back to square one. I doubt the vendors will sell me just a pin. I'll have to pay another $25 for an entire connector kit (w/pins) to get a part that should cost about 25 cents, then wait another week for it to come in. Then go through the whole PITA process again.
Find any electronic store local, one that sells cable, connectors, electrical items, maybe an electronic supply store even. Ask for a DB9 male or a female pin, which ever end you need and show the injector pigtail. The pin needs to be the same size and shape. I believe the harness side is female, the injector side is male.
They may even repair the plug for you. If not. Ask for a pin extraction tool. With the tool, you can push the pin back through the connector and remove the broken one.
There is one catch, after you cut the old one off, the wire may be to short or you may have to remove the other two and re-pin them as well. The pin crimps onto the wire after you slide the copper into the pins backside.
Then push the repaired pin into the connector, it should almost snap into place. A light tug will be needed make sure the pin is fully inserted into the connector. GO EASY, don't ham fist it, don't yank it out the back... just a nice tug to make sure it's in there. You don't want it to back out when sliding them together.
I feel your pain brother, just coming to the end of a total PITA series of events that make binge drinking a great idea. I had a oil pressure sending unit just up and fail right after doing my first 6.0 head gaskets, EGR and cooler. So when I had a sudden loss of oil pressure when running the truck through it's paces the last thing I thought of was the sending unit, hell I have only had one other one fail like this in over 30 friggin years but when I unhook the connector after trying everything else I had a fountain of oil coming out the electrical side. Really, what are the chances of it failing right then? Wanna grab a beer?
Find any electronic store local, one that sells cable, connectors, electrical items, maybe an electronic supply store even. Ask for a DB9 male or a female pin, which ever end you need and show the injector pigtail. The pin needs to be the same size and shape. I believe the harness side is female, the injector side is male.
They may even repair the plug for you. If not. Ask for a pin extraction tool. With the tool, you can push the pin back through the connector and remove the broken one.
There is one catch, after you cut the old one off, the wire may be to short or you may have to remove the other two and re-pin them as well. The pin crimps onto the wire after you slide the copper into the pins backside.
Then push the repaired pin into the connector, it should almost snap into place. A light tug will be needed make sure the pin is fully inserted into the connector. GO EASY, don't ham fist it, don't yank it out the back... just a nice tug to make sure it's in there. You don't want it to back out when sliding them together.
And for God sakes... get a light on your work!
I had one of these kits on my service truck when I worked for ALTEC, came in quit handy several times. Even rebuilt a plug for my ford dealer while my truck was in for service. If anyone knows and ALTEC mobile service tech , they all have one of these kits on their truck. Might be good to get to know one of these guys.
Oh , very good description you gave on how to rebuilt the connector.
Well, you could've paid someone to frack up your truck instead. That would have left you feeling even dumber, and with considerably less $ in your pocket.
Find any electronic store local, one that sells cable, connectors, electrical items, maybe an electronic supply store even. Ask for a DB9 male or a female pin, which ever end you need and show the injector pigtail. The pin needs to be the same size and shape. I believe the harness side is female, the injector side is male.
They may even repair the plug for you. If not. Ask for a pin extraction tool. With the tool, you can push the pin back through the connector and remove the broken one.
There is one catch, after you cut the old one off, the wire may be to short or you may have to remove the other two and re-pin them as well. The pin crimps onto the wire after you slide the copper into the pins backside.
Then push the repaired pin into the connector, it should almost snap into place. A light tug will be needed make sure the pin is fully inserted into the connector. GO EASY, don't ham fist it, don't yank it out the back... just a nice tug to make sure it's in there. You don't want it to back out when sliding them together.
Should be under the $5 limit.
And for God sakes... get a light on your work!
This sounds positive. But I'd like to not take the injector out. Is it possible to uncrimp the old pin and crimp the new one on without shortening the wire? If so, I wonder if I'll be able to do it in the small space I got in this van. Or, do they make a connector to splice some wire on after I cut it to get it to the original length?
There was someone on Ebay that was selling the coils with the plug.
I found the item but can't get the Ebay to load on the computer and the
stupid tablet version of Ebay does not show you the item number. So you will
have to do the search or wait till I get some of the stuff I am uploading to
Youtube done. I seemed to have used up all my bandwidth.
Search for : Ford Powerstroke Injector Solenoid Plug Kit (3052) New OE Injector Solenoid
That search should get you what your looking for.
Got the Auction Item Number for you >>> 171820064463
Hope that helps you out.
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