I am greatly indebted to this forum. Every time I get stuck with a problem I can get the help here. Thanks! <img src="/forums/images/graemlins/patriot.gif" alt="" />

The problem I just tracked down ended up being a brittle wire at the power transistor that was giving me a intermittent no spark problem.

BTW I am trying to figure out the best way to fix this problem. The wire broke right at the harness into the power transistor. I think I am going to need a whole harness for the power transistor. Any creative alternatives?

The truck has over 250k on it now. As I was looking over the wiring harness in the engine compartment I thought this is just the beginning of wire issues. I did some looking and I can't find a new harness for sale.

The other bigger issue is deciding to keep the truck or get something newer. I have been worried that I may not be able to get parts for the truck as time goes on. Has anyone else thought this through? I would love to keep the truck. I know every bolt on it. What do you all think?

Send a PM to Haztoys in Prescott Valley. He's able to pull rabbits out of his hat from time to time, so he may be able to direct you to a yard that has what you need.

The rest of the AZ Crew can help find parts and we're always willing to take a look at stuff if you want to meet up sometime.

Can't you just splice some wiring in to bridge your bad connection? I'm not familiar with the exact part you are referring to, so I can't picture what it takes.

John B.

Thanks Johnny. Here are the photos:




So I 'm guessing that getting a new wiring harness is not possible.

I went ahead and made a harness but it is not a permanent fix. The tabs on the power transistor are so small that making a harness for it is really hard.

Does anyone know where to get female connectors that will fit over the tabs and have room for all three?

There is usually a way to disengage the female spade from inside the connector itself. A small jewelers screwdriver or the like that you can press on a small tab to release the spade from inside the connector. I've been able to undo the crimp on the existing wire (carefully) to salvage the spade connector, and then crimp on a new wire, and insert the spade back into the connector. Takes a light hand and patience with old connectors, but can be done. The plastic can get very brittle from age, and sometimes the spade "keeper" for lack of a better word can break off.

You could try to deconstruct the female connector and see if it could be rebuilt. If it's possible, take pictures to document because this is a common issue. I've ordered a couple connectors for tomorrow that look close. I'll let you know if they might work after some testing on my truck.

Thank jinstv for the suggestion. I did not get that skill set. That would be a good business idea. If someone had the skills and the raw parts to rebuild harnesses they could be busy!

For sure hazy daze let me know!

No dice on the connectors, they're not even close. I've seen that plug configuration on other makes and models than Mitsu's. You could probably hit a salvage yard and find something that'll work.

So my 14 year old son listened to me talk about what I needed to do with the truck and he started this process and we ended up rebuilding the harness. I took photos to document the job. Hope it helps others.


Here is how my son removed the connections from the harness.


This took all the corrosion of the connectors

















[img]https://s3.amazonaws.com/MiscPhotos/IMG_3324.JPG[/img]

[img]https://s3.amazonaws.com/MiscPhotos/IMG_3326.JPG[/img]

Extraordinary offspring you have! Damn fine documentation too. Mods, this needs to be stickied for those in the future with connector maladies.

Awesome job! <img src="/forums/images/graemlins/kewl.gif" alt="" />