So the weather is cooperating, and I have a new ignition switch to install in my 69. I have wire cutters, and crimpers. (if you have read a lot of my posts, you KNOW I will over think, at every opportunity!)
For some reason I have a doubled wire in my ignition harness, and I want to try and reuse that connector if possible. I thought I had a small tube type that was the right size, but none of these connectors want to release.
Before I ruin anything, or do something stupid that will catch my car on fire, is there a trick, or cheat to doing this?
Ouch. Your ignition switch should come with pigtails, so simply splice into them. If, instead, you want to use your existing wires and new pins, the smaller size pins are still available as Mate-N-Lok, but the larger power line pins are not available. You’ll need a special crimp tool for the pins.
I would not recommend re-using your existing pins if there is exposed wiring on the back side (i.e. no insulation), as that could become a fire hazard.
Just butt-splice the two wires from your old ignition switch into the one wire pigtail. Yes, you’re overthinking things!
Thanks for the reply! I should have explained it better, what my dilemma is- the new pigtail did come with the wires attached, but for the new part, doesn’t have the same size wire in that spot- I’m ready to cut and splice, as this is the last (until the next effing thing happens!) to drive the car at least in and out of the garage. I don’t know why those wires are together in that spot. The new part isn’t the same.
The new switch is for an XR7, your old switch has a double wire as one is the pink resistance wire and should not be cut if you can help it. As you look into the plug you will see a small tab that locks the pin into the switch housing. You can insert a small common screwdriver into it (between the pin and the housing) and bend the tab down as you gently pull the wires out. Sometimes you have to jiggle the screwdriver and pull it back to get the wire out. Unless it is melted it should come right out.
Is it 69, xr7 or standard? If this is a 69 base (no tach), according to my wiring diagrams in that position there should be a pink wire (to resistor wire/coil) and green wire to park brake connector (this looks like your old connector). If it’s an xr7 harness should see red/green stripe to tach (and then resistor wire/coil) and green wire to main firewall connection then voltage regulator connector. I think the colour coding on your new pigtail is for mustang (not that it matters, just makes it harder to read wiring diagrams!).
my 69 is a standard- and thanks for noticing the difference- I’m fine with cutting the old harness, but the two wires in that one hole did throw me.
I have a couple of tube type wiring tools, but none seemed to fit it right. I guess if I swap that pin in, as it, and just cut and crimp the rest of the wires, it should be good- Thanks!
So I completed the ignition switch installation yesterday,and was glad to be able to turn the key and hear the car run again!
But for anyone else that may have trouble with the ignition switch wiring or connectors, I have two things to share about my experience.
Thing one, was the two wire in a single pin connector was throwing me off. The other thing that was difficult for me was finding the right size inside diameter tool to release the pin. What I ended up doing was modifying a common tool that both did fit the hole, and fit the pin.In this case,I cut off one of the two smaller, narrower legs. The important thing about the tool is that the pin is exactly opposite the grove in the pin. That makes it a lot easier to get them to release.
I hate that tool. Instead, I take a small jeweler’s flat-head screwdriver, and take it to the grinder: grinding one side to about half the thickness, leaving one side flat and the other side curved. I then insert it curved side out along the locking pin and the pin usually comes free after 1-2 attempts.
This Molex pin removal tool works well for both .062” and .093” connector pins. Not sure if the Ford pins are Molex, but they look similar?
https://www.amazon.com/Connector-Remover-Computer-Extractor-Sleeving/dp/B0094MIS9U/ref=asc_df_B0094MIS9U?tag=bingshoppinga-20&linkCode=df0&hvadid=80607997944720&hvnetw=o&hvqmt=e&hvbmt=be&hvdev=c&hvlocint=&hvlocphy=&hvtargid=pla-4584207577341844&psc=1
I too use a Molex tool kit for releasing wires. Mine came from Daniels corp. I also have been known to make my own release tools from appropriately sized brass tubing that came from a long ago closed hobby shop in Dallas.
Link: https://www.dmctools.com/
And: https://dmctools.com/oscar/catalogue/family/installingremoval-tools_5/
Yes, the pins are “Molex” but are now available as Mate-N-Lok. The size of the male and female pins are sightly different (male slips inside female) so a single 0.062" tool will work fine for one but not as well for the other. Believe it or not, a disposable Bic pen shell works great for male pin removals. I believe that was even in the Ford Shop Manual!
I know, that somewhere in the factory manuals, there is a reference, that shows a small diameter brass tube. The local hardware store had two smaller sizes, waay waaaay cheaper than at the hobby shop. The one that is closed on Sundays, when I was working on the car. The bic pen is a great tip. Hopefully somebody else will be able to use this thread, and the links.
Just tossing this in with the conversation. i have successfully used a small eye glass straight blade screwdriver for releasing the pin connector tabs.
Not ideal in comparison to the Molex tools that are specific for the task… but, works if in a pinch.