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Author Topic: How do I remove a spade terminal from the headlight harness connector?  (Read 3172 times)

April 02, 2014, 11:30:04 am

92EcoDiesel Jetta

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I need to remove a terminal/wire from the headlight switch to isolate the instrument cluster lighting circuit. Would a flat bladed jeweler's screwdriver work? Do I go in from the wire end or from the switch end?



Reply #1April 02, 2014, 08:12:54 pm

Gizmoman

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    AAZ 1.9, HE 200 Turbo, 82 Vanagon, AAP 5 speed
My GUESS is from the switch end with a thin small somthing.
I believe there's a barb sticking out of the flat side of the terminal that needs to be flattened a bit while you tug on the wire.
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #2April 02, 2014, 09:18:07 pm

TylerDurden

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    I have a VW problem.
Yup.

Reply #3April 02, 2014, 09:28:26 pm

ORCoaster

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    Restoring a Caddy as time and weather allows
I use a small jewelers file and it works perfect every time.

Reply #4April 03, 2014, 12:17:49 am

92EcoDiesel Jetta

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Yup.


Great answer! Now I know exactly what tool I need to make.

Reply #5April 04, 2014, 09:59:28 am

92EcoDiesel Jetta

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I tred two different size jewelers screwdrivers in the slot but it did not work. I took a windshield wiper stainless strip filed tip to chisel's edge, pushed in with pliers and got the termial out. I was surprised by the quality of the terminal. Here's a pic. arrow pointing to the lock tang.

I may haft this special tool to a handle and throw it in the toolbox so I don't have to use pliers next time.


Reply #6April 04, 2014, 10:43:36 am

TylerDurden

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    I have a VW problem.
Hella pic.  :)

for inspiration, maybe google-images: spade, terminal, removal, tool..

Reply #7April 04, 2014, 11:38:42 am

92EcoDiesel Jetta

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Hella pic.  :)

for inspiration, maybe google-images: spade, terminal, removal, tool..

Yeah, these modern phone cameras are amazing! I did a google but nothing stands out to be the right tool for this particular terminal. Ideally, the tool would push and bend the tang to release it and also push on the terminal at the same time and push it out of the housing but that would make it much harder to make. I'll just use long nose pliers to pull the terminal out from the wire end.

Reply #8April 04, 2014, 08:24:44 pm

the caveman

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I have made terminal tools from the Bosch wipers that had replaceable blades. They have 2 stainless steel guides that can be ground down to fit  and are strong enough to push the lock pins out of the way.
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