While troubleshooting various gremlins on this 93 XJ40 that’s been
sitting (forsaken outside) for a year, I’ve come to realize how
important the relays and their connectors are.
Inspecting the Big Six on the firewall has revealed a cracked clip
inside the ECM relay’s connector. So I have to take the connector
apart and crimp a new female spade-clip on the brown/blue (IIRC)
wire.
Has anyone done this and how does that connector come apart?
Also, I may have committed a cardinal error by cleaning the
connectors with WD-40. The relays absolutely balked at this… so I
sprayed some carb/choke cleaner through them to clean the WD-40
residue out. I’m no chemist, but I fear that may have added insult
to injury by mixing harsh solvents. Did I damage the wire
insulators or maybe even the soldier?
Oh, one more thing… where is the best source in the Western US
for sealed Hella relays?
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In reply to a message from MadFish sent Mon 26 Sep 2005:
Hi I found the same problem with a bunch of connectors, if you look
closely, the top of the base comes off, by releasing some clips on
the base, then with a thin pick you can push in the burb that
holds the female terminal in the base, but a better job would be
done if you find a car at a junk yard, and take the same connector,
and cot it off with about 6 inches of wire, and solder it on the
harness. as for cleaning, wd 40, and blow it out with compressed
air, then use a bit of dielectric grease. pajtas–
jaguarjoe 54 XK 120 rdstr 1961 MKIX 94 XJ6
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In reply to a message from pajtas sent Mon 26 Sep 2005:
These terminals in the relay mountings are a standard GM item: They
are available at better(read usually non-chain junk parts stores)
with good electrical sections. (Usually the same as sold to repair
GM alternator harness connectors) Clip the old one off the end of
the wire, take it as a sample piece. They are usually sold 4 or 5
to a box, for about $2. US. Make sure you get the proper one! These
are not standard .25 inch Female quick disconnects, due to their
construction. But a decent wiring section will, in fact, produce
them on the rack. They are usually brass colored, and will have no
insulation whatsoever. Just take the clipped wire end, strip it(and
I recommend tinning it with solder) carefully fold the crimp
sections over the wire(wires) and then crimp & solder. If you need
help, as the parts guy.
Scott–
The original message included these comments:
done if you find a car at a junk yard, and take the same connector,
and cot it off with about 6 inches of wire, and solder it on the
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