Crankshaft position sensor wiring (what are these little metal things for?)

447 Views 12 Replies 3 Participants Last post by peva, 9 d ago

99intrepy

Discussion Starter · 19 d ago

I want to change the connector for my crankshaft position sensor on my 1999 Intrepid 2.7 SE. This is what my connector looks like. There is a newer connector in 2000. Looks like it was redesigned. Anyway this picture is what Mopar sells. My question is, why is there 6 wires included? And what are the little metal things in the picture? Are those some kind of wire butt connectors? I can still get this at the dealer for a reasonable price. Part number 5135637AA

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peva

· #2 · 19 d ago (Edited)

Weird.

Looks like it is a kit for several applications - some for CKP, and some for throttle position sensors. 6 wires to be used 3 at a time as needed to match the gauge and colors for the various applications? See below photos more clearly showing those pieces - can't tell if they are metal or plastic - might be for connector or terminal latching, or connector keying, or shielding. My WAGs. 🤪

Maybe a Chrysler dealer has some app or installation notes on it.

Rather than 6 identical pieces, looks like 3 larger pieces the same, and 3 smaller pieces the same. You might have to get one to see where those pieces fit in the housing, and then it will make sense. Maybe 3 pieces fit that connector half and the other 3 fit the mating half, or the smaller ones insert into the larger ones, but for what purpose? Perhaps they are as you say, butt connectors for the in line splicing of the 3 wires. They seem to be a strange shape for that.

3 brands come up for 5135637AA on Rock Auto:

RockAuto

RockAuto ships auto parts and body parts from over 300 manufacturers to customers' doors worldwide, all at warehouse prices. Easy to use parts catalog.

www.rockauto.com

The apps. for the Standard Motor Products version:

Photo of the SMP version - 2nd one is zoom and crop of the first:

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99intrepy

Discussion Starter · #3 · 19 d ago

Yes those metal things I think are for wires but not sure how to use them.

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cdmccul

· #4 · 19 d ago

Those are splice connectors. Then you heat shrink over them. 3 of each of 2 different wire gauges. Use the wire color and size that matches the factory harness, and repair using the correct connectors and shrink tubing.

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99intrepy

Discussion Starter · #5 · 19 d ago

cdmccul said:
Those are splice connectors. Then you heat shrink over them. 3 of each of 2 different wire gauges. Use the wire color and size that matches the factory harness, and repair using the correct connectors and shrink tubing.

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Ok. So how exactly do those go over the wires and how do you squeeze them?

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cdmccul

· #6 · 19 d ago

Looks to me like they are designed for the special ratcheting curling crimpers. Strip wire, lay in crimp, and squeeze. The curls fold over such that they grip into the strands of copper, not just hug them flat.

But, I'd just crimp them tight with any pair of pliers, and then crimp them again with wire pliers that will squeeze in a very narrow area. Don't forget to put the shrink tube on.

The wires here aren't in a stressed situation... I don't think you'll have to worry about them pulling out.

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peva

· #7 · 19 d ago

cdmccul said:
Looks to me like they are designed for the special ratcheting curling crimpers. Strip wire, lay in crimp, and squeeze. The curls fold over such that they grip into the strands of copper, not just hug them flat.

But, I'd just crimp them tight with any pair of pliers, and then crimp them again with wire pliers that will squeeze in a very narrow area. Don't forget to put the shrink tube on.

The wires here aren't in a stressed situation... I don't think you'll have to worry about them pulling out.

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In my 45 years of electronics design and manufacturing, I've never seen a splice thingy like that. Learn something new every day. 😀

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cdmccul

· #8 · 16 d ago

Ha! As I said in the other thread, it's been a while since I've had the hood up.

I was looking for a alternator connector for a 2012 RAM truck, and read the reviews on a connector very similar connector with the same little metal u clips. One review of the connector stated those clips are “for where the connector clips to the body of the connector.“ (or something like that).

So, no idea yet. But I'm buying that connector tomorrow. I'll update if I learn something!

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cdmccul

· #9 · 16 d ago

I just bought that lot I was talking about. I'll fill you in when I deal with it.

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cdmccul

· #10 · 13 d ago

Bill,

As I expected, these are what those u clips are for.

The kit doesn't include the u clips that also grip the insulation, they just grip the copper.

Here's a picture of the crimping tool, and the bigger clips, but an example of how they look.

I've seen guys use the regular crimp tools on them, then dab solder on them. Then shrink tubing.

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peva

· #11 · 13 d ago

Those I've seen before - your typical factory production crimp - like you said: one crimp on the copper and the other over the insulation - for strain relief - in fact, exactly like the crimps on the wires in the kit photos. But those don't look much at all like the separate pieces in the photos of the kits that intrepy and I posted. But the resolution was so poor in what we posted, couldn't see much detail.

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cdmccul

· #12 · 9 d ago

There's a pic of the clips in the exact same kit. They are the crimp down connectors, just no strain relief.

And then a screen shot from the Mopar bulletin for repairing the faulty fuel pump relays in the 2008 and up TIPM boxes. You can see the crimp, and the tool.

I just did this job on a 2012 RAM 1500.

Didn't use the crimp, just twist, solder, and shrunk tube (double wall with glue liner).

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peva

· #13 · 9 d ago

cdmccul said:
There's a pic of the clips in the exact same kit. They are the crimp down connectors, just no strain relief.

And then a screen shot from the Mopar bulletin for repairing the faulty fuel pump relays in the 2008 and up TIPM boxes. You can see the crimp, and the tool.

I just did this job on a 2012 RAM 1500.

Didn't use the crimp, just twist, solder, and shrunk tube (double wall with glue liner). View attachment 43362 View attachment 43363

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OK - that finally totally cleared it up for me. Thanks.

Now when I look back at the last photo of post number 2, I can visualize what those clips really look like. Before seeing the photos you just posted, my mind was turning my fuzzy images of those pieces into really bizarre shapes totally unlike what they are.

"Didn't use the crimp, just twist, solder, and shrunk tube (double wall with glue liner)."

😁 👍

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