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Headlight failure; Headlight Failure
Topic Started: Jul 4 2014, 03:35 PM (320 Views)
ajbremer
Member
[ *  *  * ]
The headlights in my 1990 Geo Metro 4 door 3 cylinder go off and on. I found there was a lose connection at the fuse box. I totally removed the fuse blocks and believe that I've found a broken terminal within the upper fuse plug (Blue Wire). Problem is, how do you remove those terminals from the plug?

The particular plug I'm referring to has 11 wires coming out of it.

I know the blue wire is for headlights and when I slightly pull on it back and forth, I can see that the metal terminal within the plastic is moving with the wire BUT the lower part (the part that connects to the tab in the fuse box) is not moving. This indicates to me that the metal terminal within the plastic is broken in half. Problem is, I don't know how to remove these terminals. Any pics or vids would be great.
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Greywolf
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Mostly Harmless

Most (NOT all - I can see myself already getting shot down for saying every one of them) of the spade or similar metal connectors at the ends of wires push in from the back (item one)

2) When they push into place, they CLICK into place because of a small finger molded into the plastic socket that locks them into the shell.

3) If you carefully slide a thin flat item like a knife blade or very small flat screwdriver into the back of the connector alongside the metal connector attached to the end of the wire, it will push the lock finger away from the connector so it can be removed by pulling it out while pushing in with the flat object.

There are probably special tools for that called extractor number XXXX, good luck finding them.

If you are careful you can defeat the click-lock.


(ONEDIT) You may have to push out the broken part from the front, while fishing for the lock from the back


(ONEDIT-2) Great video on different kinds of connector release methods:

https://www.youtube.com/watch?v=DS4AKIoo07o&list=PLxLUprTbV9RtkBfToIccdY2Ak8kvuGNjO
Edited by Greywolf, Jul 4 2014, 08:52 PM.
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