Help removing pins!

[darelldd]

I wee bit of background. I'm a huge fan of modifying things, and never leave anything I buy the way it was when I bought it. I have a pretty well-equipped shop, and people actually regularly PAY me to do stuff for them! I have not, however, ever removed pins from automotive connectors like this.

I've been collecting all the known mod instructions for a month now, and my Prius just came in yesterday. I went right at it, and started to retrieve the extra pins from the flasher connector behind the steering wheel. I read about people "using a paperclip to start them" etc. For the life of me, I cannot get the pins OUT! And here I thought the big problem was putting them back IN for the EV mod. Ug.

I hate to admit defeat, but I've already bunged one pin up trying to remove it, and don't want to screw up more! I have all kinds of small, strong specialty tools here for some miniature work I do on LED flashlights. I have pushed on those pins as hard as I can, and nothing budges. What the hell am I doing wrong?! I'm trying to back them out (removing them as if I'm pulling them out by the wire), but ain't nothing moving!

[Marlin]

Originally posted by darelldd@Feb 16 2006, 03:04 PM
I hate to admit defeat, but I've already bunged one pin up trying to remove it, and don't want to screw up more! I have all kinds of small, strong specialty tools here for some miniature work I do on LED flashlights. I have pushed on those pins as hard as I can, and nothing budges. What the hell am I doing wrong?! I'm trying to back them out (removing them as if I'm pulling them out by the wire), but ain't nothing moving!

[snapback]210575[/snapback]

Well, I've never done it on the Prius, but assuming the connectors from which you which to steal some pins are similar in nature to the ones used inside a computer for power supply connections, it's actually pretty straight forward.

The pins themselves are usually a piece of springy metal that was rolled into a tube. There are two thin strips of metal sliced out of the pin that flare out and lock the pin in place. When the connectors are made, the pins are pushed through the back of the white nylon connector block and the two thin strips are pushed flush to the pin as it slips through the hole in the connector. When the pin is pushed all the way into the connector, the two thin strips flare out and lock the pin in, kind of like a barb on a fishing hook.

To remove a pin, you can use tweasers or long nose pliers to press the two thin strips flush with the pin, allowing it to slip back through the hole in the connector.

[efusco]

It wasn't that complicated....but it's been over 2 years since I did it and can't remember the exact technique. Whatever it was it was fairly easy though. Lemme look at my KB article and see if it triggers my memory.

[efusco]

3) 2 little clips keep a cover locked in place. Pull those apart and remove the cover. Inside you'll see lines of silver connector pins--some with wires attached, some without.

http://www.priuschat.com/forums/album_thum....php?pic_id=219
Click for full image

You should remove between 1 and 3 of those pins--2 is probably safe, 3 might be better, since if you plan to install an OEM button at some point, you'll probably need more pins for that. (You need one pin for the procedure, but it's handy to have a back-up.) To remove the pins, you can use your paper clip to start the process of sliding them out, and then they just pull right out.

http://www.priuschat.com/forums/album_thum....php?pic_id=217

Those are the instructions for that part of the process. Did you remove the cover? (gotta assume so).

If so, I'm not at all sure what's causing the difficult.

[naterprius]

I got ya covered, Darell. I have a tool for you. If you refer to the Wiring Harness Repair manual, you'll see the tools required (pdf attached).

The larger tool can be simulated using a tiny pocket screwdriver. I bought one at an electronics store for less than a $1.00.

The second tool, for the tiny pins, is harder to make. I made one the following way:

In the electronics store, I noticed a very small "test lead" connector, designed to clip on to wires or other terminals. It had a curve on the end, but was otherwise perfect. I was able to cut off the curve using side cutters. Now, I had the perfect tool. Again, under $1.00. I can send you one if you need it.

Nate

[kdmorse]

Here's the secret:

Look at this photo carefully from the instructions posted in the KB here.

http://www.priuschat.com/forums/albu...php?pic_id=217

See *exactly* where the paperclip is being applied? That is the point where you must apply pressure downward to compress the little metal latch. If you press just right, right there, then the pin will slide right out with almost no force required.

If you do not press that metal tab down, it will catch on the white plastic, and prevent the pin from coming out. All the pulling, pushing, and pokeing in the world elsewher will only result in bloody fingers.

(Obviously - I learned this the hard way)

-Ken

[benighted]

You mod LED flashlights? Do you work with the high-output Luxeons?

[darelldd]

Thanks Marlin and efusco....and Nate.

I can't see the barbs, but I'm sure they must be there. Nobody seems to mention them in the "instructions." Just, "slide them out."

Yes, I've certainly got everything apart. It was the only way to get at the pins to screw them up! I've got my small, flat driver, a small curved one, industrial tweezers, etc. But pushing on those as shown in any of the instructions I've seen doesn't do a darn thing besides deform them if I push hard enough. You don't know how embarrassing it is to ask for help with the part that should be trivial! I read the instructions and there are details on how to split the connector in half!? That I can tell by looking at it, and using my nails, presto. I have the thing open. But try to move a pin!? No sir.

To make myself feel better, I'm in the middle of doing something I can accomplish - converting the cargo light to a current-regulated 1W LED. When I'm done with that, I'll look at Nate's note and see if it gives me that little lightbulb over my head. I had to stop, or risk doing MORE damage. Grrr.

Thanks for the reply guys.

[darelldd]

Originally posted by benighted@Feb 16 2006, 11:43 AM
You mod LED flashlights?  Do you work with the high-output Luxeons?

[snapback]210600[/snapback]

Yes, that's what I mostly use. 1W and 5W. This year 10W will be released, followed by the 20W. We won't be seeing incandescents around much longer (except HID).

Here's my light page. I don't spend much time on it, so don't expect much. The automotive link might be the most interesting to this group.

http://darelldd.com/light/

[darelldd]

Originally posted by kdmorse@Feb 16 2006, 11:32 AM
Here's the secret:

Look at this photo carefully from the instructions posted in the KB here.

http://www.priuschat.com/forums/albu...php?pic_id=217

See *exactly* where the paperclip is being applied?  That is the point where you must apply pressure downward to compress the little metal latch.  If you press just right, right there, then the pin will slide right out with almost no force required.

If you do not press that metal tab down, it will catch on the white plastic, and prevent the pin from coming out.  All the pulling, pushing, and pokeing in the world elsewher will only result in bloody fingers.

(Obviously - I learned this the hard way)

-Ken

[snapback]210594[/snapback]

Aw hell! Now, I love the rest of you guys ('specially YOU Nate), but Ken here is getting some flowers. THIS is exactly what I needed to hear! I totally missed where the barb was, and WHOMP, there it is.

Group hug. This board is great, and it is because of members like all of you who jump right in and offer help