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bulkhead connector
https://slantsix.org/forum/viewtopic.php?t=21579
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Author:  Bobby Rock [ Tue Jan 23, 2007 4:53 pm ]
Post subject:  bulkhead connector

Hello,

My 74 Dart has a bad connection on the fusible link at the bulkhead connector. It's barely hanging on by threads, and the break is inside the connector. From what I can see it looks like I would need to replace the whole connector, because everything is hardwired in the connector? Which means all the wiring too. But I heard that the fusible link can bypass the bulkhead connector? What would I need to do to accomplish that? Is that even possible? Any help would be appreciated.

Author:  KBB_of_TMC [ Sun Jan 28, 2007 6:04 pm ]
Post subject:  bulkhead

All the wires may be easily removed from the bulkhead connector by gently squeezing the male pins and the pushing a tiny screwdriver into the slot to depress the tang on the female pins and sliding them out, unless the plastic is a fused mess, in which case just cut the plastic away. Many other Mopars used the same bulkhead for many years. The pins themselves can be replaced using a good crimping tool - I got mine from NAPA.

A factory manual *for the right year!!!* will show you which wire goes where. The wires did get moved around from year-to-year, even though the plastic of the connector stayed the same.

I suggest you plan to remove the underdash & underhood harness entirely (labeling the connections), and work on it while it is out of the car. You should replace any overheated, damaged, or corroded pins. I like to use a little Eastwood conductive grease on the pins to prevent corrosion; many people use white grease to keep water out the connector.

I've fixed Mopar harnesses on most of my club's raffle cars and I've never found one so bad that I couldn't fix it using a few donor harnesses.

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