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A Fix if You Break your Alternator Wire Plu

This is a discussion on A Fix if You Break your Alternator Wire Plu within the General Help forums, part of the LSx Technical Help Section category; ...

  1. #1
    Spaz is My Mentor SMWS6TA's Avatar
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    A Fix if You Break your Alternator Wire Plu

    Ok, hereís my first shot at a sticky. Long story short I was changing my alternator and I find that this plug came off with the alternator. Itís important; it tells the alternator when to charge and not charge. Without it you get nothing.


    After spending a couple hours at every auto parts store no one has it. Stealership wants me to get a whole new wiring harness. at him. So I decided to fix this. The wire came out of the plug, no breaks. So I cleaned the plug with electronic cleaner (Do not use brake cleaner, for those of you that donít know why, it eats plastic) You then need to be very carefully and take the plug apart. Remember Itís old, been through many heat/cold cycles. If you break it your really screwed. I used fine point flat tip screw driver to pop the cap off. Next I used the same screw driver to push the metal pin out.


    Next I crimp wire of similar size to the metal connector. Length of wire varies in how much you need. For me it was 4 ď long. Next I solder the two for reinforcement. Now insert the metal piece with wire back into the plug. Next slide the blue rubber seal back on and down to the plug. Replace cap and orange seal.


    Splice and crimp old and new wire together, wrap with electrical tape to cover and help secure connection and then place back into wire cover. Clip back on to your alternator.

    This is what it should look like after it is back together.




    Ideally you don't want this to break, but accidents do happen and this only cost me some solder, a new solder iron, time, patients, and electronic cleaner.

  2. #2
    ʢ ൧ ൨ ൩ ൪ ൫ ൬ ൭ ൮Ր Ց Ւ Փ Smittro's Avatar
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    I think pic 3 is a repost.. j/k
    Nice job bro!
    :\Users\Steven\Pictures\d6ftg5nh.gif


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    Spaz is My Mentor SMWS6TA's Avatar
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    Quote Originally Posted by Smittro View Post
    I think pic 3 is a repost.. j/k
    Nice job bro!
    I used it, it was a good sequence, thx, I should have credit it to you in the first post. My bad..

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    Quote Originally Posted by SMWS6TA View Post
    I used it, it was a good sequence, thx, I should have credit it to you in the first post. My bad..
    I was just messin' witcha.. I stole your pic first..lol

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    Exalted Cyclops 67CamaroRSSS's Avatar
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    Nice job.

    Only thing I would've done different is used shrink tubing in place of the electrical tape over the splice.

    And Smittro: I woulda used your sequence of events pic too. It's very good.

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    Quote Originally Posted by 67CamaroRSSS View Post
    Nice job.

    Only thing I would've done different is used shrink tubing in place of the electrical tape over the splice.

    And Smittro: I woulda used your sequence of events pic too. It's very good.
    Thanx guys! I was'nt serious I was jus playin' round.. Glad I could actually help..

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    Spaz is My Mentor SMWS6TA's Avatar
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    I installed it when I got home, it works with no problems. Alt is charging, no twitching of needle and no check gauges light.

    I thought of using the heat shrink, but it's tight and I'd need a third person to maintain control of wires while I used a heat gun.

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    Exalted Cyclops 67CamaroRSSS's Avatar
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    Quote Originally Posted by SMWS6TA View Post
    I installed it when I got home, it works with no problems. Alt is charging, no twitching of needle and no check gauges light.
    That's what I like to hear!

    Quote Originally Posted by SMWS6TA View Post
    I thought of using the heat shrink, but it's tight and I'd need a third person to maintain control of wires while I used a heat gun.
    Heat gun! We doan need no stinkin heat gun!

    Sorry I just had to throw that in there

    While a heat gun is the preferred method I've used a lighter to shrink tubing in more cases that I care to admit.

    I also have a roll of the type of non-adhaesive tape that sticks to itself similar to what they used on the cars way back when. It's been invaluable in more than 1 instance.

    The problem with electrical tape is that, over time the adhesive gives out. Be sure to check on it once in a while.

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    Quote Originally Posted by 67CamaroRSSS View Post
    That's what I like to hear!

    Heat gun! We doan need no stinkin heat gun!

    Sorry I just had to throw that in there

    While a heat gun is the preferred method I've used a lighter to shrink tubing in more cases that I care to admit.

    I also have a roll of the type of non-adhaesive tape that sticks to itself similar to what they used on the cars way back when. It's been invaluable in more than 1 instance.

    The problem with electrical tape is that, over time the adhesive gives out. Be sure to check on it once in a while.
    Farbic tape, (or tar tape) that stuff is the best (imho), electical tape ever made. They used that stuff on everything that had to be "open" sliced back then. You can get it wet and it will stuck to itself anyway.. It stay's put too.. If you wrap something up today and come back in 50 years you can peel it right off and put it elsewhere like the day it was new.. When I rewired our 100 yr old Victorian I peeled that suff off the old "knob & tube" wiring the house had it was STILL sticky... They even used it on overhead power lines because once it was (properly) stuck to itself is was wheather PROOF, not just resistant, but wheather PROOF!..


    Last edited by Smittro; 03-19-2010 at 10:38 PM.

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    i dont have a link.............but i have found the plugs on ebay.......cheap!!!!!!

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    Exalted Cyclops 67CamaroRSSS's Avatar
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    Quote Originally Posted by Smittro View Post
    Farbic tape, (or tar tape) that stuff is the best (imho), electical tape ever made. They used that stuff on everything that had to be "open" sliced back then. You can get it wet and it will stuck to itself anyway.. It stay's put too.. If you wrap something up today and come back in 50 years you can peel it right off and put it elsewhere like the day it was new.. When I rewired our 100 yr old Victorian I peeled that suff off the old "knob & tube" wiring the house had it was STILL sticky... They even used it on overhead power lines because once it was (properly) stuck to itself is was wheather PROOF, not just resistant, but wheather PROOF!..


    You may be right. That is what the power window harness in my 67 is wrapped with.

    My guess is that SMWS6TA covered his with plastic tape though.

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    Spaz is My Mentor SMWS6TA's Avatar
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    Quote Originally Posted by sjsingle1 View Post
    i dont have a link.............but i have found the plugs on ebay.......cheap!!!!!!
    what was the search you used?

  13. #13
    Spaz is My Mentor SMWS6TA's Avatar
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    Quote Originally Posted by 67CamaroRSSS View Post
    You may be right. That is what the power window harness in my 67 is wrapped with.

    My guess is that SMWS6TA covered his with plastic tape though.
    Yes...wanted something that would handle the wx...

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    http://cgi.ebay.com/ebaymotors/98-02...item53d8cb1a5a

    another.......this seller has LOTS of TPI ....LS1 stuff
    Last edited by sjsingle1; 03-21-2010 at 08:39 PM.

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    Thx for the sites..

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    Nice write-up!Thanks!

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    Quote Originally Posted by ared98ta View Post
    Nice write-up!Thanks!
    Did you use it and did it help?

  19. #19
    Junior Member ared98ta's Avatar
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    No I had already bought an over priced connector to fix.Then a week
    later I found this thread and it would have been perfect had I seen it
    first.

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    Bump..

    Ed and Mods, sinc the RSS feeds have been down, maybe look at this again for a sticky?

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