Probing automotive connectors

[Sal Bandini]

What do you use to connect to the pins on terminals? I'm not talking about back-probing connectors but unplugging the connector and measuring between 2 pins on the terminal.

I need to measure on a terminal under the dash that will be virtually impossible to do with just leads. I found some things here and was wondering if anyone uses them or do you just use extra connectors with pigtails or wires with pins crimped on.

http://www.testpath.com/Items/Test-Adapter-Kit---Connector-Pins-and-Sockets-114-602.htm

http://catalog.e-z-hook.com/viewitems/connectors-and-adapters/e-z-flex-adapter?&bc=100|1005

 

[JDon99]

In a pinch, I have used paper clips.

 

[Sal Bandini]

I'm talking about something to slip over the pin, not a piece of metal to put in connector.

 

[pi_guy]

If I check that type of connector regularly I make a break out box with M/F connectors for ease of use. If working on rare or different type of connector I use pin on wire with banana connector a setup like the lead set sold by Archie Tools a few months back.

 

[iron block]

This depends entirely on the type of connector you want to probe. If you are lucky, one of the techniques you mentioned would be perfect: find a mating connector with pigtails, or find mating pins that you can crimp test wires to.

But if you are working with some proprietary, high-density, OEM-specific connector then those approaches may not work out. A mating connector may be impossible to find; ditto individual pins.

When all else fails, a "jungle medicine" approach is to swipe a couple of straight pins from the wife's sewing kit, and push one through each of the leads that go to the terminals you want to probe. Then you can clip your test leads to the straight pins where they protrude from the wires and get a good reading.

When done testing, just remove the straight pins and the wire's insulation will typically close right back up -- or a little electrical tape as a BandAid doesn't hurt.

 

[Sal Bandini]

I'm not trying to pierce the connector and measure voltage. I am removing the connector, leaving it alone, and then trying to take resistance readings on the pins where it was just removed from.

 

[crewchief888]

I use paperclips 99% of the time

 

[Sal Bandini]

How would you use a paperclip on say something like this?

 

[popparoach]

I make leads with Deutsch sockets crimped to a piece of wire.

and insulate with shrink tube.

 

[Sal Bandini]

Thanks, do you know if some auto stores would have Deutsch connectors?

 

[BroncoSquid]

Pins like that are common at electronic stores, frys, radioshack, possibly best buy. I troubleshoot alot of connectors like that for the NAVY, I have several sets of "home made" multimeter test leads. I cut the probe ends off of a cheap set of leads and solder the correct female pins directly to the wire. That way I don'thave to try to hold the probe on the specific pin and read the meter.

 

[Sal Bandini]

Thanks I will look at some stores on my way home.

I found an entire lead set but don't want to spend $77 on something I will use every 3 years.

http://www.zoro.com/pomona-test-lea...gclid=CPHbp7mb28cCFQqsaQodpl0MvA&gclsrc=aw.ds

 

[theoldwizard1]

Go to a junk yard and cut of the male and female halves of several connectors. Getting the pins out will be a "challenge".

 

[Freeborn John]

Any car breakers nearby? An old OE connector will make the problem go away.

 

[ravenzfusion]

safety pins. push through the wiring.

 

[BroncoSquid]

That will work, seems a little pricy to me for what you get. I could hand build something that dose the same thing for less than $20.

 

[BroncoSquid]

Go to a junk yard and cut of the male and female halves of several connectors. Getting the pins out will be a "challenge".

LOL, now we are getting into pin extraction tools...$$$.

 

[torqueman2002]

Go to a junk yard and cut of the male and female halves of several connectors....

This is what I did when making test fixtures to develop service procedures for ECMs.

For advanced test procedures (ahead of production-released vehicles/components) these were very useful, because male & female terminals and connectors were not always released for production. I would go to the Bone Yard, where crash barrier vehicles were stored.

Take enough of the wire harness to easily connect your test equipment.

You are correct not to want to back probe or pierce the insulation. Long term testing show a 100% failure rate on the circuit.

I know, I know, this is a well disputed topic; but, car manufactures have the data to support the non-probe stance.

People will say they do it (pierce the wire insulation) all the time and have never had a problem. That is true, there are many anecdotal accounts, but the harness suppliers and car manufactures rely on scientific data.

 

[Sal Bandini]

It's not a question of not wanting to back-probe the connector, it's the fact that you don't do it to troubleshoot this. I am measuring resistance on a motor box assembly so that means you remove the harness and measure across the terminal pins on the assembly. This requires using a socket or sleeve, not a piercing tool.

 

[popparoach]

LOL, now we are getting into pin extraction tools...$$$.

5 bucks on amazon.
http://www.amazon.com/gp/aw/d/B00DB...ol+plastic&dpPl=1&dpID=31N7NAXE1SL&ref=plSrch
Could also use small but connecters.

 

[torqueman2002]

How would you use a paperclip on say something like this?

That's a MIL-Spec connector. What vehicle are you working on?

I used that style connector for my Break-Out-Box to test harness inter-face.

The component ends were OEM connector/harness assemblies removed from actual vehicles. Like the one below.

 

[BroncoSquid]

5 bucks on amazon.
http://www.amazon.com/dp/B003TOFNPG/?tag=atomicindus08-20
Could also use small but connecters.

Those work well but I feel they are only good for a few pins, if you know what you are doing. When I think extractor tool I am along these lines...
http://www.amazon.com/Thexton-THE588-Deutsch-Terminal-Removal/dp/B003TOFNPG/ref=pd_sim_sbs_263_3?ie=UTF8&refRID=1YBVB1TMM2H6WVRYRAVB&dpSrc=sims&dpST=undefined
Pushing metal tabs with plastic usually dosn't go well for the plastic.

 

[popparoach]

Those work well but I feel they are only good for a few pins, if you know what you are doing. When I think extractor tool I am along these lines...
http://www.amazon.com/Thexton-THE588-Deutsch-Terminal-Removal/dp/B003TOFNPG/ref=pd_sim_sbs_263_3?ie=UTF8&refRID=1YBVB1TMM2H6WVRYRAVB&dpSrc=sims&dpST=undefined
Pushing metal tabs with plastic usually dosn't go well for the plastic.

or these?

http://www.amazon.com/dp/B003TOFNPG/?tag=atomicindus08-20

 

[Dmoen]

I always make my own test leads from oem replacement terminLs. It takes some digging through all the trays of pins, but I can always find a mating connector. Always use the right connector, a gapped terminal will be a p.i.a problem to track down someday. Go to the local dealership. They will probably let you go through the trays to find what you will need.

 

[MikeF2316]

Here's what I, and a bunch of other GJ members do:

http://www.garagejournal.com/forum/showthread.php?t=268741

 

[WhiffySpark]

Here's what I, and a bunch of other GJ members do:

http://www.garagejournal.com/forum/showthread.php?t=268741

Exactly what I was going to post. I use it professionally a few times a week

 

[theoldwizard1]

They do make small alligator clips. These are from Mueller and are available from many place on line, including Amazon. Mueller clips cost a bit more, but are the best I have ever used.

 

[Bobioz1]

Google power probe AA14. That would work. I don't have one because it's a male banana end. If someone knows where to find one with a female banana end or what that type of probe is called, I would appreciate it.

 

[Bobioz1]

Or a set of those Pomona test tweezers. If you can find some with big enough tips on them.

 

[popparoach]

Here's what I, and a bunch of other GJ members do:

http://www.garagejournal.com/forum/showthread.php?t=268741

That eBay link is long dead though.

 

[Fedwrench]

Flexprobes.

Not cheap but, necessary.

http://www.jumperkits.com/

http://www.nu-di.com/springs.htm

http://www.tooltopia.com/waekon-77202.aspx

http://www.tooltopia.com/waekon-77203.aspx

 

[MikeF2316]

That eBay link is long dead though.

Find member ArchiesToolShop on that thread and send him a PM.

 

[GTA Matt]

Find member ArchiesToolShop on that thread and send him a PM.

From what I understand, he can't get those kits any more.



I know it wasn't the original intent of this thread, but it was brought up: anybody piercing wires with a probe/needle/paperclip/etc., needs to be kicked in the nuts.

 

[Sal Bandini]

That's a MIL-Spec connector. What vehicle are you working on?

I used that style connector for my Break-Out-Box to test harness inter-face.

The component ends were OEM connector/harness assemblies removed from actual vehicles. Like the one below.

That was just an example of how I have to measure the pins, not insert a paperclip into a connector.

 

[stroked93]

I work at a caterpillar dealer. We have the Deutch connectors in Stock

Sent from my SM-G900V using Tapatalk

 

[Brownsfan]

From what I understand, he can't get those kits any more.



I know it wasn't the original intent of this thread, but it was brought up: anybody piercing wires with a probe/needle/paperclip/etc., needs to be kicked in the nuts.

I agree. And add to the list those who try and shove their meter leads into a connector pin then it opens up causing a loose connection . That's why you need the proper back probes to test at connectors. Goes back to what the OP was asking.

 

[Sal Bandini]

OP (me) was asking for sockets to go over pins, not something with pointy end to jam into orifices.

 

[nine4gmc]

Is this for one particular vehicle or all vehicles in general? If for one, find a salvage vehicle and cut the female plug off with a few inches of wire, pug it in to your connector and probe the pigtails.

 

[Karnage]

Put a piece of thin heat shrink over the end of your probe and shrink it away from the tip, this should give you enough wiggle room to slide it onto the pin you want to test. I t might take a couple of goes to get the size you're looking for.

 

[Sal Bandini]

One connector