Getting wires back into a connector - car plug disassembly

[TUS373]

Had an oops today whilst working on the car. Pulled a piece of trim and discovered it had a plug under it. Removing the trim has yanked the wires out of the crimp connectors.

Rather than just trying to push the wires back in, that will no doubt be futile , I really think I need to recrimp then.

Please can anyone tell me how this plug comes apart?



I expect it is concerned with the blue tab but I don't want to break it.

Thanks in advance.

[TUS373]

[TUS373]

[Smiljan]

Lever out the blue piece and the terminals should be able then to pulled out of the connector.

[TUS373]

Thanks. Does the blue part come out entirely or lever up from the groove? As you can tell, I don't want to break it.

[ian332isport]

TUS373 said:

Thanks. Does the blue part come out entirely or lever up from the groove? As you can tell, I don't want to break it.

From the shape of the blue bit, I’d say it will hinge up but stay attached. Quite often the plastic bits are a secondary lock to doubly secure the pins. You will still probably need to get in there a small screwdriver, or preferably a dedicated pin extraction tool to release the pins.

[TUS373]

Thanks for the reply. I will examine it very carefully. No idea how to re-attach the wires in there as I assume that the crimp will need opening slightly, wires inserting, then closing up again without disturbing the overall shape. Bit tricky all said especially as there is a whole car on the other end of the wire.

[Smiljan]

Yep, as above it looks like it's hinged on this connector. They do a myriad of different types.

Do you know what it was connected to and more importantly do you know which wire goes to which terminal?

[ShampooEfficient]

Take the metal pieces out of the plastic plug and crimp on some new connectors. Only a couple of quid for a pack and means it's done properly. Youll have to see what type they are once out (ie male or female).

[TUS373]

Thanks again all. Yes I know which colour wire goes where. The connector is power supply for lamp under an automatic gear shift. It provides the illumination to show whether in P/N/D/R.

Just been reading up about it and studying YouTube. I do not possess a crimp tool and not got the plug apart yet. If I can get the pins out, I don't have replacements and would not know what to look for. Other problem I can see is trying to crimp terminals back on to the short wires popping up near the transmission. I am thinking maybe I rewire the plug with new pieces of wire, then crimp/heat shrink back on to the existing wires.

Total pain. Wish I had not touched it now. New territory for me and has the hallmarks of microsurgery that my eyesight and patience cannot take!

[Gary C]

Would be easier to buy a new one.

I can see its made by JST but cant read the type number from it ?

Is it readable ? Its possibly a HC type ?

RS do replacement crimp pins, but dont seem to carry that connector, but with the number we might be able to find it.

Also, often you can solder the core to the crimp pin rather than muck about opening it up, but you need to ensure it will still fit in the plug body.

Edited by Gary C on Saturday 1st January 11:24

[Smiljan]

Which car is it for? Sounds a pain due to location more than the actual issue being a pain.

If it's just a 12v light I'd go with your original plan to spread open the contacts and use some pliers to just re-crimp them again. As you say though, seems the wiring was very short to start with so might be tricky to access to do this.

Is it possible to do a bit more trim removal to get better access to the wires?

[TUS373]

Thanks again everyone. The code on the plug looks like JST then C.D or GD or OD. That is studying it with a loup. It's tiny.

The plug is from a Corvette so General Motors.

[D_G]

Dead easy, flip up the blue tab, insert very thin (preferably a correct tool) pick of similar in the front of the connector alongside the terminal to push the lock tab in and it will come out of the back can then open up the end and reconnect the wires or solder on, make sure the tab is bent back up before reinserting the terminal.

[TUS373]

Thanks. Pulled the blue tab up. Looking down into the plug now. Two sets of holes. In the photo below, the lower set have the contacts. Is it this holes that a pick tool needs to go in. If so, what orientation? I assume there is one barb so top or bottom but don't know.

I don't have the pin extraction tools but see they can be had from Amazon.

[Bodo]

It's likely a JST HCM family connector; the extraction tool is a simple rod-type like this https://shop.t-g-s.de/en/shop/f595/ But you won't need that - take a stiff wire instead.

Chapter 7.4 of the JST HCM Handling Spec shows an x-sec of the female contact chamber https://eu.mouser.com/pdfdocs/HCMHandlingManual.PD... and explains how to disassemble.

[TUS373]

Thanks - I am back on the case now, like a dog with a bone. I am thinking it is a JST HCH connector, and was just looking to see how to take the pins out.

Presumably, need to push something into the front in the holes above those with the pins in.

[Bodo]

Yes, and pry the housing lance a little (Ch. 7.4):

[TUS373]

Thanks Bodo. I studied the manual earlier it was very helpful. I had a go but bottled out. I am thinking of buying some similar connectors and pins from RS Components. I cannot find a 3 pin / 3 way / 3 circuit connector the same anywhere, including JSTs own catalogues, so some equivalents would help me practice. If I break the one I have, I think I will struggle.

[Bodo]

TUS373 said:

.... I am thinking of buying some similar connectors and pins ... I cannot find a 3 pin / 3 way / 3 circuit connector the same anywhere, including JSTs own catalogues, so some equivalents would help me practice. If I break the one I have, I think I will struggle.

Understand, that's why I thought it was the HCM series, because the look similar to yours, and they are available as 3-way. HCH only seems to be available in four and nine way.

I found them online here
3way plug https://eu.mouser.com/ProductDetail/JST-Automotive...
contact 20-22 AWG https://eu.mouser.com/ProductDetail/JST-Automotive...
contact 24 AWG https://eu.mouser.com/ProductDetail/JST-Automotive...
contact 26 AWG https://eu.mouser.com/ProductDetail/JST-Automotive...

I found that this is the cheapest crimp pliers that actually work for these small diameters: https://www.aliexpress.com/item/32847747241.html