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Electrical Connectors

Bulletin 3003

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Application

All aftermarket electrical connectors available from WVE

Overview

This bulletin will detail tips to ensure proper installation of a WVE aftermarket replacement electrical connector

Procedure

WVE offers many aftermarket replacement electrical connectors. We receive numerous questions concerning proper wire orientation. On many of our aftermarket replacement electrical connectors the wire color will may not match the wire color of the connector it is taking the place of. The color of the wire and connector is irrelevant, but the gauge thickness is critical. A smaller gauge wire will not be able to handle the load that a larger gauge wire can and may lead to an overheat condition and possible fire.  When installing a new connector, it must be wired in the same manner as the OE connector. To correctly install the new product, cut one wire at a time matching the new connector cavity to the old to ensure the proper circuits are being connected. In cases that the old connector is damaged to the point that you cannot tell what cavity a certain terminal was originally installed, a factory service manual with connector views or schematics will need to be obtained. For example, in the picture below the orange wire could be identified as the number one cavity and should match the location on the new electrical connector.

To install the new connector, it is important to cut one wire at a time in a staggered length pattern. The staggered length pattern will allow the wire harness to lay flat and not have a mass of repairs in one area which will allow a cleaner looking repair and prevent possible interference with items around it.

Solder and shrink tube are the best repair choice, but a crimp style butt connector is an acceptable alternative when used with shrink tubing to protect the connection. A wire nut, blade style or scotch lock are never a recommended choice to make a clean permanent connection. Attaching the new connector to the old harness should be done by stripping the insulation away on both wires you will be connecting, this will allow you to use a solder iron and solder to permanently bond the two wires while making a lasting, low resistance connection. Shrink tubing over the newly bonded wires is required to prevent a short circuit and to prevent corrosion. Remember to install the shrink tube before the wires are soldered together.

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