Replacing damaged ignition switch wires...

[GreggK]

I'm getting around to replacing some damaged wires at my ignition switch. I have spare wires from past vans I'm using. For the most part I've been able to remove the donor/damaged wires, except for the sleeve terminals in the connectors, at the back of the fuse panel. I've been using an extractor tool from a Weatherpack kit I have. I've been successful at using it on other connectors on the van until now. I did bend the tool once and thinking maybe that's what's keeping me from going in far enough to remove the sleeves, but also some of the wires have a larger sleeve terminal. So first... is this the correct tool? Second... what tool am I looking for, to remove the larger sleeve terminals in the red fuse panel connector? Thanks for any advice.

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'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[MarkWard]

The factory tools are similar to the weather pack tool, but the factory tool has a provision for pushing the connector out once the outer tangs are depressed by the tool.
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[GreggK]

Thanks Mark,
Would you know if the Weath pack/factory tools, are similar to Molex ectaction tools?
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'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[MarkWard]

Sorry I don’t know. If you had success with your tool, it’s possible the distortion is keeping you from inserting it enough to release the terminal end.
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[ALIKA T3]

The thing is with these US tools, they're technically sized for imperial connectors, making it a slightly tight fit in the plastic housing.

I have one with an ejector like Mark said, but it's still tight into the plastic, therefore not a perfect release on the locking tangs.

I find it really hard to find the correct tools, I think there was a German brand offering a full kit a while back, but it was like a grand for them, and I can't even find it anymore.
Same with crimpers, I wish I could find crimpers for big barrel/small wires like some done by VW on the fuse panel, or some meant for double ganging different gauges.

I can still get it done but it's time consuming...
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Syncro transmission upgrade parts in the Classifieds.
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http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[GreggK]

Yea, I can never get the 2 wire into one terminal as good as I want it, with my crimpers. Been using all the tools that came with a Weather Pack kit I bought years ago. Alika t3, are you saying they make a specific crimper for the double wire application?
I've ordered a few extraction tools. I'll post back with my findings. Fingers crossed!
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'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[MarkWard]

If I can remember tomorrow I’ll post pictures of my extraction tools and factory crimper.
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[GreggK]

Thanks Mark.
_________________
'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[ALIKA T3]

[GreggK]

Here is one of the ignition wires I'm replacing. Luckily I have a few spare harnesses that I'm taking the complete wire from end to end, no splicing, but the thick red/blk double wire from the ignition switch, which you can see in the picture, is different. My van is an '86, donor wires are from an '87. The thick red/blk comes out of ignition as a single on the '87, then the thinner red/blk comes back into play at the red connector behind the fuse panel. I think that thinner wire goes to the seat belt/brake warning light connector. I'll figure it out but first I need to get that extractor tool!

_________________
'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[Steve M.]

Electrical Terminals
3 piece kit £27.
https://brickwerks.co.uk/product/tool-electrical-terminal-and-connector-removal-set/


Amazon VW/Audi Terminal tool kit $100
https://www.amazon.com/Steelman-95928-10-Piece-Terminal-Tool/dp/B007QV2MXY

Universal kit. $50
https://www.amazon.com/dp/B0C7VN572V/ref=sspa_mw_d...p13NParams

As always on Amazon scroll down to read reviews by people who bought the items.

EDIT: The $50 kit has better reviews then the $100 kit

The "Snap On" equivelent for the VW 1978 KIT is only $1,300 and some ridiculus amount!
https://vw.snapon.com/SpecialToolsDetail.aspx?itemid=50320163.

Double Edit: The VAS 1978A kit has been superceded up to version "C". Only a mere three thousand something from "Snap On"!

VW shop tool p/n: VAS 1978 (from reading the reviews.)
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[GreggK]

Steve M... that Amazon set looks like it will have the correct tool for the bigger barrel terminal, or close. I'm supposed to get two extractors I ordered tomorrow. If those don't work I may invest in that set. Thanks for the link!
_________________
'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[ALIKA T3]

I have a similar kit that looks like the red Amazon kit, I bought it just for the big rounded extractor, and same issue as all the other ones, tight fit in the plastic housing.
All others have garbage soft crap.

For the small round pin, I have a used tool with an ejector I bought on eBay, it's tight but it's strong at least! I forgot the brand, I'd have to go look at the shop.

I had another one that didn't last long, I think from Digikey, but found elsewhere. It's good for a few used then the tube comes off the handle, you bend the ejector rod etc....
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[Chugach]

[MarkWard]

Posted to the wrong thread. Here are my wire tools and VW crimpers. The red one is spring loaded for larger connectors AMP 725 938. The smaller one was likely from Baum tools or another supplier. AMP 305183-R

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[GreggK]

Thanks for the part numbers Mark. I was able to find each one of the extractors for sale and made the purchases. The first extractor I bought to replace my bent Weather pack tool was just a little bit bigger than my bent one and won't fit but it does work on the connectors I've bought from VC/RMW. I'll post the results from each purchase I made, once everything shows up. Also some pretty cool stuff on the Baum website.
_________________
'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[jlrftype7]

Not much help here, but these are my old style Round Pin removal tools.
I think Assenmacher sold them in the 1980s.
I have two of the same size, as once the Aluminum gets bent, you're kind of screwed with that tool...

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'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto

[GreggK]

Another step forward. The AMP305183-R tool came this weekend and YES it does remove the smaller barrel terminals from the connectors on the back of the fuse panel. Thanks for that info Mark Ward. Still waiting for the larger extractor tool.
I came across another challenge while on the wire replacement/repair mission. I traced a damaged wire back to a single fuse holder. Has to do with the dash illumination lights. To do the cleanest job, I'll need to remove that wire/terminal. Only way to describe it would be a terminal that will accept a blade from an ATC fuse. I used google search and saw a type of extractor tool for ATC fuse terminals, but can anyone verify a part number for the correct tool and terminal type. Picture shows what I'm working with. THANKS!

I found these through a search but since I can't remove the original to see, I'm not sure if it's what I need.
https://www.ebay.com/itm/155481477112?chn=ps&s...cNM6Pp56Xs
_________________
'86 2wd Poptop transplant
FAS TDi engine swap. Peloquin LSD
https://www.thesamba.com/vw/forum/viewtopic.php?t=692188&highlight=slow+but+steady

[MarkWard]

I have made small extractors from wire coat hangers. Take a section and flatten the end with a hammer on a vice. Then grind to get the width. Sometimes bending the flattened slightly end to get more leverage. I don’t recall dealing with the individual VW fuse holder though.

They do sell inline fuse holders and unless your going for concours restoration would just splice one in. They sell them for different types of fuses so you can keep it standard.
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[crazyvwvanman]

VanCafe sells a bunch of useful parts for wiring work.


https://vancafe.com/fuse-holder/

Mark