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Originally Posted by 97 Boxster
I was thinking if the harness was a little more snug at the connection that this would solve it. Any ideas??
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if wiggling or applying pressure at the connector has influence on the behavior/fault of the problem, then the root cause should be there and not some distance down the harness.
the electrical connection within the connector is with a pin and a socket. it is possible that one socket have become "larger" so that the pin/socket is not making good contact. I think this is not likely. connectors for use in harsh environment is designed to have the body of the connector take the load so that the pin/socket do not. by the time the connector body is locked in place, pin/socket should be making per-design contact with no mechanical stress.
it is possible that moisture has gotten into the connection and making one or multiple contacts dirty. but since you have mated/demated this connector many times, it should have rubbed the rust off.
it maybe that one socket at the harness end is not fully seated in the connector. Take a look at the harness connector and see that all electrical connections (sockets) are at the same level.
I still think the problem is with the connector pins/DLM PWB solder joints. These pins at the PWB also functions as a mechanical anchor for the DLM side connector; so wiggling the harness will wiggle these pins.
any chance you can take apart the DLM and post close up photo of the solder joint?