openinverter forum

I've got an oil pump controller with wires that are too short to add onto. I'm struggling to get the old wires to release, does anyone have any tips on getting the darn things out?

I would solder fresh wire on but the end is short and my soldering is messy.

The white piece on the "front" is a terminal postion assurance (also known as TPA). You need to figure out how you can pop it forward.

Pins will probably be retained by the black housing itself with some simple one way spring barbs that you push down to release the terminal. This is why the terminal only is visible through part of the cavity. Get yourself some terminal removal tools and a magnifying lamp.

This is a huge connector so it should be easy, I had to do this on connectors of below 2mm pitch, that is a real challenge not this monster of a connector.

tom91 wrote: ↑Tue Nov 28, 2023 9:27 pm The white piece on the "front" is a terminal postion assurance (also known as TPA). You need to figure out how you can pop it forward.

Pins will probably be retained by the black housing itself with some simple one way spring barbs that you push down to release the terminal. This is why the terminal only is visible through part of the cavity. Get yourself some terminal removal tools and a magnifying lamp.

This is a huge connector so it should be easy, I had to do this on connectors of below 2mm pitch, that is a real challenge not this monster of a connector.

Thanks, I knew I needed to find the release barbs, I didn't know I needed to pop off the TPA but will do.

Are the pins themselves relatively generic? Or will I have to remove the old one and move it to new wire? I caved and tried to solder it but either my iron or solder or flux are terrible as I couldn't get the wire to tin at all.... On the large or small wires ...

Thanks Tom, the white TPA popped off with a little force then everything else came out easily.

All pins look super generic so better get the calipers out and look for manufacturer marks on the connector or crimps.

Probably a Japanese manufacturer.

Fairly sure ( actually 100% certain ) it's made by Sumitomo. Toyota part number 90980-12483.

Ive had no luck finding a replacement for the larger pin. I suspect the smaller ones are generic but I've not confirmed yet. Large pin has B1 stamped on it but that's all. 9.5mm wide but a particular shape and a unique locking system rather than a tab on the pin itself....

Unique a plastic latch into a pin? Someone is new to wiring.

seems close this one: It is: (literally my first look for it without any effort, Japanese terminal rough dim, then construction method)
https://www.auto-click.co.uk/8100-0452

You need to take more accurate dims of it

Also a good site to do some browsing on https://www.corsa-technic.com/category. ... gory_id=54

https://www.kinkong-connector.com/products/90980-1248311pinfemalewaterprooftypeautomotiveelectricalconnectors-ID989.html

tom91 wrote: ↑Wed Nov 29, 2023 6:29 pm Unique a plastic latch into a pin? Someone is new to wiring.

seems close this one: It is: (literally my first look for it without any effort, Japanese terminal rough dim, then construction method)
https://www.auto-click.co.uk/8100-0452

You need to take more accurate dims of it

Also a good site to do some browsing on https://www.corsa-technic.com/category. ... gory_id=54

Thanks! Got to ask how you found it? I spent a long time googling various sumitomo options but that looks right to me!

Look for site selling connectors and terminals. use brain to sort through them, big terminal +/- 9.5mm, then just scroll till you find something close.

It's Sumitomo. Kinkong are Chinese copies. It's also used on the elecric power steering contoller on many Toyotas/Lexus. If you look on your connector next to the <PBT> mark there is the Sumitomo logo. It looks like a blooby diamond with a hole in the middle. Fairly easy to find using google image search.

Here it is in use with EPS, https://www.pakwheels.com/forums/t/elec ... rk/3007775

Here's an ebay link https://www.ebay.co.uk/itm/254457557974 ... 78eeddeba8

Ok Tom et al, here's your chance to make me feel really stupid.
This is the data/resolver connector for the GS450H oil pump controller to the oil pump.

I've got the same issue of the wires being too short and my soldering being too sloppy to get a reliable connection.

I've removed the white TPA thing that locked the pins and removed one of the little rubber bungs (in 1000 tiny pieces). Each pin hole has another smaller hole that I assume is to release it's pin although I can't see anything. Try as I may with the little pins and other pokey things I have, I can't seem to get it to release....

Is there anything I'm potentially missing? There is 4 other holes at the front that look like they might do something, two top and two bottom.....

Anyway, got any ideas?

https://www.auto-click.co.uk/5-way/sumi ... /6189-1046
https://www.auto-click.co.uk/8100-3455

Yes I think it's probably easier in this case just to replace my one, especially as I'm already ordering pins from them.