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Author Topic:   Amphenol connectors
NewportMe posted 03-26-2010 05:02 PM ET (US)   Profile for NewportMe   Send Email to NewportMe  
Could someone explain how to place a new rubber boot over one of these connectors? I received my new wiring harness and one of the rubber boots over the female socket is the wrong size. Evinrude was nice enough to send the correct boot but the one on the harness is too large. I need to swap the boot for the smaller one that was provided. Are there special tools involved?


davej14 posted 03-27-2010 04:20 PM ET (US)     Profile for davej14  Send Email to davej14     
Without knowing the specific type of connector, some have removable pins which require a removal tool. If you take them out be sure to write down the wire color and position beforehand so you will get them re-installed in the proper position.
jimh posted 03-27-2010 11:21 PM ET (US)     Profile for jimh  Send Email to jimh     
Precisely what connector you're asking about is not clear to me. In general, with a rubber molded connector body, to change a hood you would probably have to disassemble the connector pins from the body, slip the hood over the wires, reinstall the wires and connector pins to the body, and then slip the hood over the connector.

Can you post a picture of the connector you are talking about and the hood you want to install?

NewportMe posted 03-28-2010 09:36 AM ET (US)     Profile for NewportMe  Send Email to NewportMe     
Jim, and Dave,

Thanks for the replies. The connector is a single pin with a black rubber boot. The wire is 18 ga. I think, the black boots are perhaps 3/8" in diameter. After much research on the internet I found the pin removal and installation tools for around $90 for the set. After contacting several Evinrude dealers in the area and trying to borrow the tools, or get a tech. to swap the rubber boots for me with no success,I decided to use forgo purchasing the tools and use crimp on "bullet" connectors. Given the potential for high voltage to be present I used heat shrink connectors, then installed another 2 layers of heat shrink tubing with adhesive over the connector each a little longer than the last. Last night I tested the Kill circuit at the house on muffs and everything works properly. Hopefully the extra steps I took with regard to the heat shrink will hold up in the long term...time will tell.

Thanks again,


jimh posted 03-28-2010 12:00 PM ET (US)     Profile for jimh  Send Email to jimh     
Usually most circular contacts for connectors where the contact back-loads into the connector body can be released using a tool which:

--consists of a very thin wall circular tube just large enough in diameter to fit over the connector contact

--inserts into the front of the connector

--releases a springy tab or flute on the contact which is retaining the contact in the connector body.

I certainly would not pay $90 for one. MOLEX connectors typically have release tools as I described above, and they shouldn't cost more than $5 to $7.

NewportMe posted 03-30-2010 04:58 PM ET (US)     Profile for NewportMe  Send Email to NewportMe     
If you search e-bay under this:Amphenol Pin Tool Set P553-2700
you will see what I believe to be the tools I would have needed. I thought $90 was excessive as well, that is why I made the repairs as stated above.


seahorse posted 03-30-2010 05:14 PM ET (US)     Profile for seahorse  Send Email to seahorse     

You can easily make your own removal and install tools using appropriately sized brass tubing from a hobby shop, the insert and glue the modified tubing into a wooden dowel for a handle.

I've also see a roll pin half ground down that fit around the pin or socket to insert them into the Amphenol connector.

Use rubbing alcohol for lubrication of the rubber.

jimh posted 03-31-2010 08:29 AM ET (US)     Profile for jimh  Send Email to jimh     
Many thanks to Seahorse for the wonderfully important reminder to use alcohol as a lubricant when trying to assembly connector bodies made from rubber, such as the Amphenol connectors used on many OMC or BRP engines. That is a very important step in the process. It is quite amazing how wetting the rubber connector components with alcohol will ease their assembly.

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