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-   -   Pin terminals on wires in CLU plug (http://986forum.com/forums/boxster-general-discussions/74362-pin-terminals-wires-clu-plug.html)

stomachbuzz 01-13-2019 11:55 AM

Pin terminals on wires in CLU plug
 
So, I'm going through my '97 986 project.
Cleaning up the immobilizer/CLU system.

I removed the M535 box, and it's actually mint inside. Either it's been recently replaced, or the 1 in 1m chance it somehow didn't get wet.

The black connector is a different story.
The plug had visible corrosion residue on the outside, and the pins inside were discolored.
I bought a pin terminal removal tool, and have removed the individual wires.
Most of them came out fine, but I ruined 3 pins in the process. Additionally, 4-5 pins need replaced.

I cut into one of the wires, and found black copper oxidation even ~8 inches down. I may have to really hack into this harness and replace a bunch of wiring.

The main issue I'm having is how to get new pin connectors. I eventually found a Porsche part #, but they range from $3-7 EACH!
Other, less unique, pin connectors are $3 for a package of 100 or more. This is really a "10 for a penny" item on the Chinese industry market, but I can't find this specific pin (how it's tanged) anywhere else.

Anyone have tips on what I can do to re-construct this harness and retain it's reliability?
Possibly buy an entire pigtail and solder each wire on?

https://i.imgur.com/ThaCa2Sl.jpg
https://i.imgur.com/SxcxUI8l.jpg
https://i.imgur.com/55efMepl.jpg
https://i.imgur.com/xNIpyJbl.jpg
https://i.imgur.com/vWEnW39l.jpg
https://i.imgur.com/nNg2FjEl.jpg
https://i.imgur.com/SqaVpu7l.jpg

Also, on the other plug going into the CLU (which has about 40 wires), I noticed 2 of them are taped together. Looks like an official job, but I'm hesitant to believe Porsche did this from the factory.
The two wires spliced together are the front-most wires going into the plug that are solid white and solid grey.
https://i.imgur.com/cXi6NJ5l.jpg


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