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EV Switch - A Cautionary Tale

Discussion in 'Gen 2 Prius Accessories & Modifications' started by DanCole42, May 16, 2005.

  1. DanCole42

    DanCole42 New Member

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    So I got my factory EV switch from japanparts.com, and I was going through the installation. Everything was moving along a lot easier than I thought it would be... it was a breeze.

    Then it comes time to insert the wire and connector into pin 27 of the HV ECU plug.

    The connector (which I stole from the steering while flasher) just will NOT go in all the way - and yes, I have the white thing pulled up. I push too hard, and the wire snaps off the connector and the connector gets jammed into the plug so thoroughly that the plastic bulges. I try putting a paper clip in the other end to try and push it out, but it won't move and I don't want to break the plastic any more.

    Hoping that I got the connector far enough down to make a connection, I try soldering the wire to the tangled mass of metal now in pin 27. It's impossible to get in and the plastic starts to melt, so I abandon THAT solution.

    So fortunately I didn't damage the rest of the plug, and the car works fine, but it looks like I'll never get to use EV mode. Anyone have any suggestions?
     
    #1 DanCole42, May 16, 2005
  2. DanMan32

    DanMan32 Senior Member

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    Maybe too much solder on the pin for the wire?

    Yep, it is next to impossible to get that pin out once it is in.
     
    #2 DanMan32, May 16, 2005
  3. Torf

    Torf New Member

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    Is there ANY metal from the pin sticking out of the hole in #27? If there is, you should be able to wrap a stripped thin wire around the pin, and use electrical tape to keep it in place.

    Sure, there is a risk that the connection may come loose, but you could probably get it pretty secure with tape. The tape may come loose over time, so if the function of the EV switch becomes erratic, you could retape the pin.

    Since I don't have a picture of the plug, it is hard to say if this would work or not.
     
    #3 Torf, May 16, 2005
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