Fuel pump harness repair
#1
Fuel pump harness repair
Here's a brief write up on how I repaired my fuel pump harness.
I replaced my fuel pump in June 2011. A few days later it quit on me while driving. After some troubleshooting I determined the multi-plug wasn't making good contact at the fuel pump. I sourced a good used harness from RoverDude. I installed it with a tiny shim to help keep it tight and in place. It was good for 9 months, many thousands of miles, and numerous wheeling trips. A few weeks ago I started experiencing problems again. The fuel pump would cut out intermittently with no rhyme or reason. Jiggling the plug at the pump would get it running again.
I was very irritated, in a hurry to repair for a trip, and didn't want to dish out $200 for a new harness. I also wanted a more permanent fix, one that was easily field servicable too.
I decided to cut off the two plugs from the wiring harness. I grabbed a pack of very small female spade connectors from PepBoys. I crimped a connector onto each individual wire and used heat shrink to seal it to the wire insulation. It's a pretty tight fit where the multi-plug connects to the pump and I was concerned about the metal on the connectors touching accidently and shorting something out. So I cut tiny lengths of some very small diameter heat shrink and slid it over the outside of the metal part of each connector. I pushed each wire home onto the male spade on the pump and it fired right up.
I've had zero problems since, total cost was about $7 for the connectors, and I feel confident in the repair because I did it and its simple.
The old plugs:
The fix:
Ta da!:
I replaced my fuel pump in June 2011. A few days later it quit on me while driving. After some troubleshooting I determined the multi-plug wasn't making good contact at the fuel pump. I sourced a good used harness from RoverDude. I installed it with a tiny shim to help keep it tight and in place. It was good for 9 months, many thousands of miles, and numerous wheeling trips. A few weeks ago I started experiencing problems again. The fuel pump would cut out intermittently with no rhyme or reason. Jiggling the plug at the pump would get it running again.
I was very irritated, in a hurry to repair for a trip, and didn't want to dish out $200 for a new harness. I also wanted a more permanent fix, one that was easily field servicable too.
I decided to cut off the two plugs from the wiring harness. I grabbed a pack of very small female spade connectors from PepBoys. I crimped a connector onto each individual wire and used heat shrink to seal it to the wire insulation. It's a pretty tight fit where the multi-plug connects to the pump and I was concerned about the metal on the connectors touching accidently and shorting something out. So I cut tiny lengths of some very small diameter heat shrink and slid it over the outside of the metal part of each connector. I pushed each wire home onto the male spade on the pump and it fired right up.
I've had zero problems since, total cost was about $7 for the connectors, and I feel confident in the repair because I did it and its simple.
The old plugs:
The fix:
Ta da!:
#3
I do plan on cleaning the contacts up though. The problem is the tight space. So I figure I'll use an old trick from when I would super-tune my baitcaster fishing reels. Get a Qtip with a wooden shaft. Insert it into a Dremel tool and apply a dab of metal polish. Then gently polish the contacts.
#4
I just went through all this with mine-my condolences to you. I ended up having to go gack to the connector over the rear left wheel and run new wires all the way to the tank. Discovered a really nice wire harness. It is 6/14 all in a rubber sheath-much like heavy black extension cord. It is from truck wiring and was sold by the foot at NAPA.
#5
I just went through all this with mine-my condolences to you. I ended up having to go gack to the connector over the rear left wheel and run new wires all the way to the tank. Discovered a really nice wire harness. It is 6/14 all in a rubber sheath-much like heavy black extension cord. It is from truck wiring and was sold by the foot at NAPA.
#6
Join Date: Mar 2010
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I just went through all this with mine-my condolences to you. I ended up having to go gack to the connector over the rear left wheel and run new wires all the way to the tank. Discovered a really nice wire harness. It is 6/14 all in a rubber sheath-much like heavy black extension cord. It is from truck wiring and was sold by the foot at NAPA.
That sounds good. I was an Aviation Electrician in the USN 1971-1975.
I also worked both as a Manufacturing Engineer and a Reliability Engineer on both the MX and Cruise Missile Programs.
You can go a step further and more or less "fab" your own protective backshell by forming a small mold with either a good stiff tape or similar material and adding RTV to serve to keep the wires from shorting out and to keep future contamination from getting to the connections.
A little food for thought.
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