[V8] How to disconnect connector blocks?

Professor GT gmail CavalloGT at gmail.com
Sat Feb 18 09:25:07 PST 2012


Radek,

The terminals (the metal ends crimped to the wires, that latch into the plastic hardshell connectors/junction blocks) typically have tiny barbs that latch into equally tiny ramps molded into the plastic cavity of the hardshell. The smaller the wire gage, the more microscopic they become. For more senior folks like me this means I have to break out the magnifying glass!
Anyway, there are special "removal tools" which typically are nothing more than specialized flat picks. Most modern hardshell connectors also have secondary plastic locking wedges which have to be removed before the terminals can be picked out (released). Honestly, I can't recall if the V8 has any of these secondary lock wedges in the connectors, other than possibly the ECM/TCM connectors, but the point of it all is that without having the proper picks usually the poke and pry method only damages the hardshell and the terminals to the point that they are unusable and require replacement. 
Also, the purpose of relaying the headlight circuits is to limit voltage drop to the lamps so they burn the brightest they possibly can, and to limit current flow through the switching circuits to extend their lives indefinitely. This is done by locating the relays out under the hood such that the high power circuit from battery power through the secondary side of the relay and on to the lamps is as physically short as possible. The trick is using relays I'm a protected/sealed enclosure, and locating them where they are best protected from road spray.
I have yet to tackle this project on my two V8s but before they get put back into service you can bet it will be done. 
I have drawn up a modified factory schematic for this and if interested let me know and I can provide a download link. If I had more time I'd like to put together a complete conversion kit for doing this, but right now I'm working really crazy hours and it doesn't leave me much time for anything else, let alone working on my V8. Once Spring gets here I'll just have to schedule some vacation time to decompress and get my V8 therapy in!

OWDEE-ON!

GT

Subject: [V8] How to disconnect wires from connector blocks?
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I've been trying to relay the headlights, using relays from my parts car, together with their respective connector blocks.  The idea is to place the relays inside, on the existing panel, away from the engine compartment, moisture, etc.

However, I want to change some of the wires in the connector blocks for thicker ones.  To do this, I've been trying to pull wires out - I used small nails, pins etc. to unlatch the wires - without any success.  I'm talking about  connector blocks that have four (in this case) wires in them, all female fittings, that fit into a standard Audi relay with spade connectors. I don't want to destroy the plastic block, just to replace some of the wires that fit into it.  Is there a trick to it, or a special tool? 
Thanks.

Radek.
91 V8Q 5-sp.

Thanks,

ProfessorGT
(Sent from my iPhone4)


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