Hi, I have to replace an oxygen sensor on a friends 2004 Dodge Stratus. While I was testing the sensor, I noticed two of the four wires on the connector the sensor plugs into where broken off. Instead of just cutting off the old connector and crimping a new one on, I think I'd rather just crimp two new terminals on the broken wires and reinsert them into the connector, but I'm unsure where to purchase these connectors from or even what size to look for. Can anyone tell me what size these connectors might be? I'd really appreciate any advice you can give me.
Questions about repinning a automotive electrical connection
- Thread starter jgelack
- Start date
Check out https://www.bmotorsports.com/ fot tools and materials, I have used them GM. I have never done electrical on a modern Dodge
htmdude57
Well-known member
Picture didn't show up.
Wrench97
Well-known member
What kind of access do you have to the harness?
It's a real pain in a tight space to and you need the correct crimping tool, for a 04 I would just splice them and heat shrink.
It's a real pain in a tight space to and you need the correct crimping tool, for a 04 I would just splice them and heat shrink.
Not the best access from under the car. I'm thinking that if I remove the passenger wheel and go at it from that direction, I might have better access. Or possibly trying to fish the connector to the top of the engine compartment, that would be about the best case scenario.
BillK
Well-known member
The connectors are probably available from the dealer but finding a parts guy to look them up might be a problem. The parts stores around here actually have some of the more common ones but you have try and figure them out on your own.
I agree with you in that I would rather do the repair the way you want but in the real world most shops would just get a new "pigtail" and crimp and heat shrink the wires and call it a day.
I agree with you in that I would rather do the repair the way you want but in the real world most shops would just get a new "pigtail" and crimp and heat shrink the wires and call it a day.
Jay H 237
Well-known member
You'd also need the tool to release the old pins out of the connector. Many times if you push or force them out they'll dig out some of the plastic ridge that holds them in, then the new pins don't always seat. When you plug the connector in the pins are pushed out the backside.
wssix99
Well-known member
The connector should have a brand name stamped on it. Can you read it?
Depending on the brand, you can search a catalog and I.D. the connector series and model. From there, you will need special tools to remove the old terminals and special crimpers to properly crimp the terminals.
The proper tools will cost you several hundred dollars. The terminals will cost you a few cents with $10 for shipping. If you don't want to make a big investment, then the solution would be to use a new pigtail with quality barrel crimps, which you can use with an off-the-shelf crimper.
Depending on the brand, you can search a catalog and I.D. the connector series and model. From there, you will need special tools to remove the old terminals and special crimpers to properly crimp the terminals.
The proper tools will cost you several hundred dollars. The terminals will cost you a few cents with $10 for shipping. If you don't want to make a big investment, then the solution would be to use a new pigtail with quality barrel crimps, which you can use with an off-the-shelf crimper.
firebirdparts
Well-known member
Napa tends to carry these. It might take some doing to find the right one. There are lots of other vendors and I don't really know who's best. This looks interesting:
connectors.dcctools.com
Just shows what repair kits they make, and how many different versions there are.
Mopar Connection Repair Kit
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I'm not really interested in spending a couple hundred dollars buying the tools needed to do this. I'm just doing this as a favor for a friend. Looks like alot of the replies suggest just crimping on a new connector for a reason, so looks like I'll be going that route instead. On a positive note, I already have all the tools and supplies to do this! I never would have thought repinning the connector would be so involved! Thanks for all the great advice guys!
Two resources for Chrysler electrical connectors I have used before:
Official FCA / Chrysler / Mopar websites.
Mopar connector repair kits:
connectors.dcctools.com
MOPAR Wiring Harness Service Connector Manual.
Official FCA / Chrysler / Mopar websites.
Mopar connector repair kits:
Mopar Connection Repair Kit
MOPAR Wiring Harness Service Connector Manual.
dcg9381
Well-known member
There's a tool for this. It's not expensive.
For custom projects I use GM weatherpack connectors.. If you were going to re-connector, that's what I'd use (but it's also what I know best).
Noltz
Well-known member
If it's a POS old Dodge, just cut the connector off completely and **** connect it. If it's in decent shape buy the right O2 sensor or get a scrap one.
I had a heater go dead in my front O2 three months ago. I had a known-good O2 with damaged wiring from another Honda. Cut, crimp, and 4 heat shrinks later I saved $100. Works fine. Heater circuit wires don't care what way they're wired but the sensor wires probably do.
I had a heater go dead in my front O2 three months ago. I had a known-good O2 with damaged wiring from another Honda. Cut, crimp, and 4 heat shrinks later I saved $100. Works fine. Heater circuit wires don't care what way they're wired but the sensor wires probably do.
For future reference…………..Many signal wires for O2 sensor are shielded ………….so **** connection may or may not work. That ground shielding must to dealt with.
Same with CANBUS signal wires that may connect to 2-60 modules or devices in the vehicle
Same with CANBUS signal wires that may connect to 2-60 modules or devices in the vehicle
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Wrench97
Well-known member
When is the last time you saw a shielded connector on a O2 sensor?