Best way to repair these wires?
01-07-05, 10:12 PM
#1
Best way to repair these wires?
This is the 1-2 switch on my tranny. The wires are quite hard and have worn thru down at the plastic part of the switch. It was nearly this bad before setting down the tranny, but now they're either broken or about to break through. The neutral switch wiring is close to this bad too.
Before I go cutting into the plastic end and trying to find some bare wire to resolder, anyone have any tips?
Dave
Before I go cutting into the plastic end and trying to find some bare wire to resolder, anyone have any tips?
Dave
01-07-05, 10:17 PM
#2
TRINGLS
Join Date: Apr 2004
Location: Clermont, FL
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I actually just ripped mine off as I wasnt using it in the swap. 
I dont believe repair is possible due to the way the case is on the sensor. If you find a way I'd love to know for future referance, my reverse sensor is weak.
~Kris
I dont believe repair is possible due to the way the case is on the sensor. If you find a way I'd love to know for future referance, my reverse sensor is weak.~Kris
01-07-05, 10:54 PM
#5
These wires have been baked from heat rising off the cat and into the tranny tunnel.
I spent some time with the dremel and knife doing excavation. Basically the four wires dive into a rubber chunk that is wrapped by a black plastic surround. It's just a big solid hunk of rubber and plastic - I can cut away some to expose a little more wire, but barely enough to solder. Even if I solder it, I expect it will be fragile afterwards. The rubber makes for a very cruddy strain relief, especially considerng that the piece gets screwed into the housing, but the wires don't like to twist.
Dave
I spent some time with the dremel and knife doing excavation. Basically the four wires dive into a rubber chunk that is wrapped by a black plastic surround. It's just a big solid hunk of rubber and plastic - I can cut away some to expose a little more wire, but barely enough to solder. Even if I solder it, I expect it will be fragile afterwards. The rubber makes for a very cruddy strain relief, especially considerng that the piece gets screwed into the housing, but the wires don't like to twist.
Dave
01-07-05, 11:37 PM
#6
Original Gangster/Rotary!
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Just buy the new sensor. Over the years I have slowly replaced lots of that little stuff. Installing the new engine wiring harness gave me a particular sense of satisfaction 
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01-08-05, 07:28 AM
#8
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I guess the best plan would be to order the new parts. That said, I fixed the same problem in mine last spring using the Dremel and knife method. After I soldered the broken wires I built the plastic back up with JB weld. It has held up fine so far, even in the hot Houston summer. If it breaks again I will replace the part.
Tom
Tom
01-08-05, 04:13 PM
#9
Obsessed
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Ah, JB Weld - God's gift to do-it-yourselfers. I've reinforced/patched/built up several electrical connectors with the stuff and it works great for a hack.
And yes it is a good insulator also
And yes it is a good insulator also
01-08-05, 04:16 PM
#10
Well I think I got the neutral switch (4 wires) fixed ok, but the other two were in rough shape also. Instead of rubber, the wires are embedded in plastic on those. Whatta bugger - I think I need to get all new ones. Just because of poor connector design.
Dave
Dave
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