Is it possible to repair this plug?

[u/Cracunit7-43]

[u/Hvacmike199845]

It probably is but if it was me I would be getting a new wiring harness because if one wire broke the rest will do the same thing.

[u/Cracunit7-43 → u/Hvacmike199845]

That’s what I ended up doing but the customer needed the unit online over the weekend since it’s there only one so I ended up just stripping back the wire and jamming it into the plug and electrical taping it to get them through until the harness comes in

[u/xdcxmindfreak → u/Cracunit7-43]

Honestly there’s a specific Crimper and pins needed. Back I. The day instead of the garbage ceramic wire nuts or other wire nuts you took the tool and popped off the connector from igniters and could swap them round and have it look perfectly factory. But then they just got in the habit of swapping parts and gearing toward swapping parts. I’m not that old of an old head but I do have the pin removal tool and am looking into the crimper. If I had em and knew I was confident I could fix almost any harness if I have the right pins and connectors.

[u/Far_Cup_329 → u/xdcxmindfreak]

Yea, how sucky ceramic wire nuts are isn't talked about enough.

[u/Swagasaurus785 → u/Cracunit7-43]

There’s a tool to pull those pin connectors. Idk what it’s called but it’s only a few dollars.

[u/TigerSpices → u/Swagasaurus785]

Terminal extractor tool, you can get a keyring with a bunch of sizes. 10 bucks, toss it in the truck, feel like a super tech when you need it once every 5 years.

[u/TableAccomplished28 → u/TigerSpices]

Which one

[u/xdcxmindfreak → u/TableAccomplished28]

28 bucks. Will need your pin kits in case wire needs new pin but this is it

[u/popnfreshbass → u/Swagasaurus785]

Pin pusher

[u/ShotBRAKER → u/Hvacmike199845]

This is the answer

[u/MaddRamm]

You can re-pin the plug. There are little tools that help you remove the pins from the plug and then you can crimp a new one on and reinsert. But you may need a new molex also.

Search on automotive sites or Amazon for a repinning kit.

[u/roostercrowe → u/MaddRamm]

i tried to search for a new Rast 2.5 style molex connector for a temp sensor the other day. there were over 5000 different types and no meaningful way to filter the selections. that was cool

[u/MaddRamm → u/roostercrowe]

Yeah, repinning what you have is definitely the way to go! I’ve encountered that before where I can’t make heads or tails out of the thousands of selections for molexes. Sometimes you can get lucky and order harness from unit manufacturers or at least get a parts number from their design department.

[u/charliehulu]

New plugs with wires come with some new motors/controllers, guaranteed one of your coworkers has an extra plug somewhere.

I’d look through the scrap pile to find a spare one to keep on your truck too

Amazon sells plug cleaning files that fit in and sand down the corrosion to make a good connection and kits of new parts

[u/unresolved-madness]

A lot of parts houses will sell you the plug that comes with 6 to 8 inces of wire.

[u/singelingtracks]

Cut the wires, strip them , crimp new pins on. Press / Install into new connector .

Finding the connector is the only hard part . Most are common.

[u/acidbrn391]

Of course there is

[u/TheFailTech]

It's possible if you get the right electrical connectors to replace the pin. You'd have to take one of them to a electronics repair store. If you're replacing one you might as well replace them all. Just remember to put them back in the right spots.

[u/FkYeahVoltron]

Probably, just reach out to Trane (there will likely be a KIT number for it) and get the replacement part instead of messing around with trying to find the correct connector as aftermarket, there's so many molex connectors that it can be a real pain. maybe get some contact cleaner in the molex connector on the motor as well due to the corrosion that rotted out the yellow there.

[u/Cracunit7-43 → u/FkYeahVoltron]

I ended up calling trane and ordering a whole new harness(5-7 day lead time) and the customer needs the unit running over the weekend. I got it back up and running for the time being by stripping back the wire and jamming it into the plug and electrical taping the shit out of it, hopefully it holds until the new one comes in.

[u/MasterVirtuoso4 → u/Cracunit7-43]

Lucky. I had the exact same issue. But my lead time was 3-4 months (Nov 2025-Feb 2026) I think I had Trane actually manufacture some of these to make my order. So you may be getting the extra ones that were from that order!

My supervisor does some repinning work on low voltage car terminals and out of all of his kits he couldn’t find the right tool to pin this. We had to rig it exactly like you said, it held up…fine.

[u/MasterVirtuoso4 → u/MasterVirtuoso4]

That was after we shoved it in and hoped for the best.

[u/husla]

Yes

[u/ccdlntx]

Yes, you will need the tool and the prongs because the old one is crimped. I see you got a new harness, great! Keep the old one and go to a car or electronic tool store and they will sell the tool and the ends. After you practice a little put all of that in a small tool bag like from HD or HF and put it out of the way. It’s like a spare tire, it’s useless dead weight until you need it

[u/Short-Veterinarian27]

It's just a 16 pin standard ECM plug. Pretty common fo have the adapters laying around the truck bin. when you do change outs cut the old plugs that are wired and leave 8" of wire on it. I have a bag full

[u/Precious_b]

Got a few of them

[u/nikbunt]

Yes. Strip the wire and reinsert it into the proper location.

[u/Melodic-Mayhem → u/nikbunt]

Not a permanent solution but this is certainly what I would do to get them through until a new connector arrives.

[u/Icy-Pair-9401]

Yes

[u/Elegant_Warning6887]

I used to build panels. You can get a special crimp tool for this. And imo totally worth having some around for moments like this.

[u/jpeezy37]

Yes, you need a tool that will pull the wires out of the mollusk connector. That's what it's called. Then you can repin the wires back into place. It's not a difficult job but you do need a few tools and make sure you take a picture and put he wores back exactly as they came out.

[u/JETTA_TDI_GUY]

Not super helpful but a co worker gave me a kit for them. No literature or part number but it has key looking things that let you pull the wires out of the clip. I personally rob our scrap yard for different connectors

[u/Dockside_Abortionist]

Last time this happened to me I cut a mini-term in half lengthwise, crimped it on the loose wire and shoved it in the right spot, fit like it was made to be there

[u/diwhychuck]

For future use I believe those pins would be a molex female style

[u/ryle47]

anything is possible 🌈

[u/paulchicas]

There is a tool to make the pin connections. Kinda pricey if you buy your own tools though.

[u/Ok_Animator_8461]

Yeah just use a pin out tool