Hello! I bought a new-to-me '77 last month, and for the first few drives everything was fine. One night we went to a restaurant, and I left the lights on (and none of the 30 people who came in after me had the courtesy to tell the hostess "hey there's a car with its lights on outside...").

Anyway, we got home no problem, but the next morning, the car was dead. No power at all, not even brake lights. Figuring I drained the battery, I had it charged and tested, and everything came back good. However, still no power to the car at all. No lights, no start.

I'm new to working on cars, so I've spent the last 3 weeks working on this off and on, but I believe I've tracked the issue to a partially melted connector. But first the basics.

I have 12.6v at the battery, at the starter, and at the high speed blower relay. I have 0.0v at the alternator, and 0.0v at the fusebox (should I have any when car off?). I have checked the lone fuseable link I found near the starter, and its good. (There are a number of aftermarket items in the car, so there is a chance the previous owner 'customized' the wiring).

One cable from the starter runs to a connector that sits under the master cylinder, which then goes to: the alternator, the high speed relay, and the hood light. The alternator part of the connector has melted, and the cable no longer makes contact with the metal plate in the connector. Here's a photo annotated with some voltages.



Does anyone have any idea what this connector is called or where to find a replacement? In looking at the factory wiring diagram, the connector is labeled, "2984415" but that is for the non-AC configuration. Mine has AC, so I think its part number "8900635", but the 'with AC' diagram is not as detailed, so I'm not sure.

If anyone can help me on the part, I would appreciate it. Also, there's a chance I'm way off on this, so if anyone has other suggestions for a '77 with no power, I'm happy to hear them. I have found a lot of threads on this already, but none have helped my issue.

Thanks!

 

you could try these sources

http://www.lectriclimited.com/mainpage.htm

http://www.repairconnector.com/categ...OR-CONNECTORS/

 

This thread saved my butt today.

 

commented on the first post not realizing it was an old thread,

Glad this thread helped you out,

Neal

 

First off - glad this was of help! Second - sorry to have bad poster etiquette - I never replied to my own thread with my solution.

I clipped out the entire connector, put the blower motor relay cables in one end of a crimping tube, then the cable from the starter and the one to the alternator in the other end. The lightbulb socket on the hood was physically damaged and wouldn't hold a bulb, so I just clipped that cable out of the car. Used a mini torch to apply some insulation, and its never been a problem since.

 

Found this post this morning. Using your 2984415 & 8900635 numbers found that the 8900635 was in stock but with a minimum order of 19 @ .55 ea.
When you removed your old Tap Connector, did you find it to have the hood light cavity extension built into the main body of the 8900635? Almost looks as if both connectors were used as one to tie-in on A/C cars?
The other number you posted 2984415 has the extension but out of stock.
Good to see you solved your issue.

2984415 Link: https://www.connectorpeople.com/Connector/DELPHI-PACKARD/2/2984415

8900635 Link: https://www.connectorpeople.com/Conn...ARD/0/08900635

 

My faux pas was shorting out the terminal lug on tha alternator when I was working on something in that area. I fabricated a 3-way connector to replace the original, don't need the blower motor connections because I have installed a Vintage Air system. Then I put an insulating cap over the lug to keep that from happening again. Chevyman you originally mentioned that there is an related active thread going on, that didn't show up on a Google search, this old thread did come up when I entered in the connector part no. which is on the Willcox schematic tracer. KC_CO your annotated photo of the connector and the results of your wire tracing saved me a bunch of time and effort, thanks for that.

 

I don't remember, and unfortunately I didn't hang onto the old connector (or at least I cant find it).

 

My connector looks exactly like the one in the original post, with the hood light lead. Doesn't look like either of those two replacement parts have it. The 2984415 number shows up on the Willcox schematic, is this another 1977 one year only part?

 

If you look at the A/C section of the Willcox line diagram, just above the RPO C-60 Air Conditioning text you will see the 8900635 connector mentioned in KC_CO original post. That's why I asked if the two connectors were somehow connected or seemed connected to each other. I believe you will only find that connector in the first photo on early or 1st design built cars.

 

If you look at the early or 1st design 1977 hood light assembly you will see the 2984415 connector attached. The 8900635 connector then snaps into the 2984415 connector interlocking both connectors.
Early 77 Hood Light Assembly: https://www.ebay.com/itm/1977E-Corve...EAAOSwhktau6~~