Date:         Wed, 2 Nov 2011 14:04:00 -0700
Reply-To:     Alistair Bell <albell@SHAW.CA>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Alistair Bell <albell@SHAW.CA>
Subject:      Re: D15 connector revealed
Comments: To: Kim Brennan <kimbrennan@mac.com>
In-Reply-To:  <5DA26185-CCF6-43E7-981C-B14155F9FF19@mac.com>
Content-Type: text/plain; charset=us-ascii

Yes, I made an attempt at cleaning the contacts. I made my own molex removal tool a while back (http://shufti.wordpress.com/2010/02/28/multi-prong-connector-tool/), found the overheated connector to be reluctant to come out. I have a range of molex connectors, but none of the larger size used on the van, need to stop by the shop.

alistair
On 2011-11-02, at 12:16 PM, Kim Brennan wrote:

> I've replaced one of the connectors on the back of the fuse panel (the one the fog lights go through). There are devices for extracting the pins, and you can get replacement pins from digikey, or mouser. The main issue I found is that the existing pins can oxidize. Once they have oxidized they're not going to be able to carry as much current as originally they could. That difference will be revealed as heat at the connector, which ultimately browns/melts the plastic housing. 
> 
> I tiny metal bottle brush that can fit inside the female pins, will remove the oxidation. A rolled up piece of emery cloth or very fine (1200 grit) sand paper can substitute. 
> 
> 
> On Nov 2, 2011, at 2:08 PM, Alistair Bell wrote:
> 
>> Due to the no start situation I had yesterday, I pulled the fuse panel and had a look at the D15 connector. Pics and some text here
>> 
>> http://shufti.wordpress.com/2011/11/02/vanagon-d15-connector-issue/
>> 
>> spoiler: the connector showed signs of overheating.
>> 
>> alistair
>