[Shop-talk] automotive connector breakout wires

[David Scheidt]

> On May 23, 2024, at 00:00, Steven Trovato <strovato at optonline.net> wrote:
> 
> I need access to the individual pins in automotive connectors.  Sometimes there are other approaches like back probing that work.  But other times I need to actually reach into the connector and connect to a pin or socket.  Most recently I was working on the power running boards on my Ford Expedition.  I wanted to apply 12 Volts to one particular pin and ground to a different pin to actuate the motor.  Switching the two makes the motor operate in the other direction.  That's how the running boards extend or retract.  Fortunately, the two pins I needed were separated by an unused pin location and I was able to use some jumper wires with small alligator clips.  That worked out, but if the pins had been adjacent I wouldn't have had enough room.  I see there are some breakout wire sets available like this: https://www.amazon.com/HT306-Breakout-Leads-Diagnostic-Oscilliscope/dp/B07QXZ79J2. This particular one seems to be designed to connect to an oscilloscope, which is not my situation.  There are also sets of automotive pins available like this: https://www.amazon.com/Connector-Terminal-Automotive-Electrical-Removal/dp/B0CRR3GGF1/ref=sr_1_3. I suppose I could make my own wires as needed.  So, what do you guys use for these situations?  Of course next time it will probably be a different car and pins will probably be a different size and/or shape.  I am sure I won't have every possible size and type, but I'd like to be able to cover a lot of the possibilities.  Have you found something that works for you?  Thanks.
> 

When I was working in a shop, we cut connectors off of things when we replaced them, with as long a tail as possible.  They got used for testing, and I depinned connectors to have individual wires for testing etc. I often ended up having to make what I wanted. 

For some components, connector pig tails are available at reasonable price, those are great for this. 

If I were still working in a shop, I probably would spring for a connector kit from aeswave, or someone like that. It’s going to have bananas on the end, but that’s easy to deal with, with a banana to bare wire or crocodile clip.  They are expensive kits, though.