So it seems my wire harness is rotting away in my 96 lt1.. I have had atleast 4 connectors just kind of fall off so im guessing the whole thing will probably be the same, just curious if anyone knows where I could look for a whole new harness or if I should rebuild mine..

Thank you,
Charles R

 

I'd do the connectors to the components as they fail. A new harness is likely out of the question and a used is well - more of what you've got. Which have already failed you?

 

What I did was to just replace the plastic connector shells. You push the pins out of the oid shell and put them in the new shell and you're done. That way you don't have to deal with splicing wires and related stuff.

I had a fire in my car and many of the connector shells were melted:

 

Hi Cliff - Don't want to hijack the thread but where do you get the connector shells - are they available new? Also, is that tool in your picture used for removing the wire terminals/connectors from the plastic shell? If so, where can I get one - would be neat to have around. TIA

 

Replacing just the connector shell works well for some but on the later C4's some of the connectors are assembled with "pull to seat" so a person would need to cut and replace the terminals on those.

The connector shells and correct tools are available from many sources and "better tools" provide substantially better results. If you've a larger project look in the rear of Book 2 of the FSM and the majority of the connectors are identified by "type/style", you would want the correct release tool and a crimper that would accomplish both the terminal and the seal crimp for that particular "type/style".

You can use your favorite search for Delphi or Packard style tools and terminals.

If you don't understand terminals and connectors EFI Connection does both connectors and pieces (their terminology). Their $25 minimum isn't great but it's very easy to ID most of the under-hood requirements from them by just using the correct engine type in their search tools. I don't buy from them but theirs is a very good research tool.

This should take you to the correct are to be searching from:

http://www.eficonnection.com/eficonn...rPigtails.aspx

They have all of the Delphi terminals also by type/style

http://www.eficonnection.com/eficonn...nalSearch.aspx

Those 2 links and the rear of your Book 2 should educate you. There's many places to buy and many locally - there shouldn't be a need generally for Internet purchases.

 

thats a good idea cliff, but unfortunatly some are so bad the old shell just falls off the wires.. so I find it might be just as much work..