Fusebox Bulkhead Pins

[WesD]

87 2.5, the pin for the power wire corroded enough that it broke off the pin for the C100 bulkhead connector.  I can't find any pins that fit it, which one works? 

 

I have an old connector from a GM truck but the pins are a little different in size. 

[ghetdjc320]

I’m pretty sure the pins are a Delphi (Aptiv) design as that’s what most of the truck uses. @cruiser54 or @Minuit would probably know the exact pin you need. 

[Minuit]

I cannot confirm with absolute certainty that that's a Delphi (now called Aptiv as of a year or two ago) connector, but it shares some very similar features to bulkhead connectors in the Delphi catalog. Unfortunately, on a Renix era Jeep there's roughly a 50/50 chance that it's a readily available connector from a respectable brand or some absolutely random garbage that nobody has thought about in 30 years that looks remarkably similar to something you can still buy.

 

Look for any moldings in the connector that say "PED" - that would confirm it 100%. The mixed Metri-Pack series come in four different connector sizes, which each have several variations depending on wire gauge.

 

Some more pictures of the pin that broke off, or where it's located in the connector, would help - assuming it's something you can still buy.

 

 

[WesD]

in the connector, look where the hole is (top center, second pin down).  That's where the red wire in the background connects to.

 

I was trying to fit in a male spade connector (see bottom of connector), it's almost the same size but it's not long enough to fit through.  I think it needs to be at least 1".

 

I doubt it's a Delphi because those have a hole, and this one is solid.   I'm going to try to make a delphi one work.  

 

 

[schardein]

Those don't look like the standard terminals I'm used to seeing in the bulkhead connectors- however most my experience is with Jeep CJ and 91+ XJ/MJ stuff.  But, if you look closely at the width of those terminals, some look like the more common 1/4" wide male terminals which are series 56 Packard (Delphi, Aptiv) terminals.  They happen to work with standard hardware store 1/4" male/female disconnects.  

 

However, some appear to be wider- which will be Packard (Delphi, Aptiv) series 59 terminals.  At 5/16" wide, they are made to carry more current, and are commonly used in a few spots in the bulkhead connector, in a few spots in the ignition switch, and in the headlight bulb connectors.  

 

Again, the connector in the front of the picture doesn't look exactly like a Packard 56 or 59 male connector, but it might work.  The part number for a 10-12 gauge male series 59 is 08917322, 14-16 gauge is 08905807.

 

Can you confirm the width of the terminal you are wanting to replace?

Also, I'm curious how those terminals lock into the connector?  How are they removed?  

[WesD]

My next post will contain the pictures.

 

I ordered Packard 56 terminals from ebay, I got 6 for $5.     They don't work exactly because they're too wide.   I had to do a little mod to the power wire (12V from battery), as there is corrosion on the end and I'm going to end up splicing a little extra wire in there to get some slack.  

Tomorrow I'll get my dremel tool and try to shave a little off the sides, and then they should fit OK.

I wouldn't be surprised if this is a Ford-sourced fusebox, as the connectors look nothing like the GM trucks I've worked with.

Even a male spade quick disconnect connector should work fine, assuming it was long enough.

 

The blue grid is the wire lock, it holds the pins in place.  

I'll do a full write-up once I get this done.  

 

[WesD]