I haven't looked at the bulkhead in a while (as its been raining fairly non-stop) and the FSM doesn't really cover this.

So can anybody tell me how a wire that goes to the bulkhead connector is supposed to be replaced? Do each of the wires and clips come out the back like the turn signal switch? Or is it trickier than that? And if the wires come out, is there a place to buy new terminal connectors and what type/size are they?

Also, if it matters the car is a '66 Dart.

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'66 Dodge Dart

If you look carefully, you'll find that the wires are crimped to special connectors that clip into the plastic shell. It isn't hard to release the connectors if the wiring harness is out of the car - the male side you squeeze slightly and it slips out, the female side you need to use a very small jewler's screwdriver to push down the tang and let it slip out. I've found the right connectors at NAPA and other places, but take the old one along to find a match.

If it's just 1 damaged wire, you need to unplug the bulkhead connector and for the engine side use needle nose pliers; for the passenger cmpt. side you are probably better off releasing it from the firewall (2 screws I think) and working under the dash.

If the plastic is melted from overheating due to corrosion (very common), you may have to replace the plastic housing; the same housings were often used in a variety of models.

Thanks! So I took a brief look today while I was cleaning the contacts. The contacts do wiggle and seem like they would come out cleanly. But I'm still a bit fuzzy on exactly how each individual wire detaches from the connector. I don't want to pull out the wire and leave a connector behind...

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'66 Dodge Dart

Each male and female connector is crimped onto the wire, and the connector just clips into the plastic. The metal connectors are similar to the very common 0.187" space connectors, but are designed to have a small tang that sticks up on the female ones and the male have a cutout in the blade that allows the blade to expand slightly - if you look closely at the connector (admittedly hard with the bulkhead in the car) you'll see what I mean. \

A standard good quality crimping tool (not just pliers) is all you need to put a new connector onto the wire. To get it off, you'll have to very carefully open the crimp up (very difficult) or just cut the wire off as close to the crimp as you can and strip and make a new crimp - there's plenty of slack in the harness for that and that's how I do it. It is very important to make a good solid clean connection.

It's a lot easier with the harness out of the car, but still possible to do it with it all in the car.

Took me to forever to find the part number for these so for future reference.

The bulkhead terminals can be had at NAPA under part numbers NW 725145 (male) and NW 725147 (female) each for $0.69.

If you asking for them somewhere else the common name would be GM 56-series terminal (possibly also called Packard 56 terminal, not sure if they are the same size though).

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'66 Dodge Dart

Packard 56 is correct. I purchased a 100 count package each of male & female #56 terminals from Ron Francis wiring. Price was much lower per each.

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67' Dart GT Convertible; the old Chrysler Corp.
82' LeBaron Convertible; the new Chrysler Corp
07' 300 C AWD; Now by Fiat, the old new Chrysler LLC