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Date:         Wed, 14 Oct 2009 18:14:07 -0700
Reply-To:     neil n <musomuso@GMAIL.COM>
Sender:       Vanagon Mailing List <>
From:         neil n <musomuso@GMAIL.COM>
Subject:      Wiring Harness Plug Repair
Content-Type: text/plain; charset=ISO-8859-1

Hi all.

In repairing the wiring harness on my Jetta swap, getting damaged wires out of the plugs was initially a mystery. I can't see for sure in my Bentley if the Vanagon uses these plugs, but likely they have the same type of contacts.

Found this page on releasing wires from VW wiring harness plugs:

Some neat pics and info. Here's the type of tool to use:

Haven't read the page entirely yet, but one thing I found useful, was to push the wire in so the wings were easier to compress.

A while back I had tried the proper tool at my parts place. I asked my parts guy and discovered that the tool was pricey. So I ended up using a paper clip to remove these types of contacts. It was a kludgy, but with a careful hand it worked.

But today, ran into a snag replacing the 4 wires in the coolant temp sensor plug.

Even after removing the little silicone plugs 3 wires didn't come out.

As a LAST RESORT, with wires snipped flush, I inserted my fetid paper clip tool, held the plug firmly to the bench, and lightly tapped out the contact with a suitably sized nail, point filed flat. (I'm sure there is a more eloquent drift one could use!)

Yes the wings likely scraped the plug on the way out, (I had called in advance to see if I could get a new plug) but even with this butcher-like technique, I found that the new contacts "clicked" into place and stayed put.


-- Neil Nicholson '81 VanaJetta 2.0 "Jaco"

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