Working on a 1991 Toyota pickup, 3L V6, automatic and about 160K miles on it. Need to change a bad TPS and came across this problem. It seems that one of the wires on the connector to the TPS sensor has come loose from the plastic part. Tried to spread the little ears on the metal part, didn't work. Still pops out when connecting the connector. It appears that there is some sort of material just behind the metal part in the back of the connector to prevent the metal part from coming out of the plastic part. My question is what is that material and what can I do to repair the connector? My idea is to put some epoxy behind that metal part in the back like the other locations have. Would this work? Any other way to fix this other than to







buy a new connector? Hopefully you can see what I am talking about in the pics. Appreciate any ideas!!!

 

You might be able to buy a new connector. Or just replace the terminal. Let me do some checking around to see what's the best replacement option. I'll post back ASAP.

 

Usually there's a little tang on the metal part of the connector (the part that's crimped onto the wire) that holds the connector in place in the housing. Look carefully at the metal part and see if that tang is either broken off or mashed down so it doesn't catch the housing anymore. If it's just mashed down you can carefully bend it back up with a small knife blade so it will work again.

If not, you can do the epoxy thing, but that makes the connector harder to repair later. Alternatively you can get a connector repair kit and replace the crimped on piece. Some folks on this forum know where to get such a thing - I don't.

 

If the metal connector and holding tang/tab are good you could go to the junkyard and carefully remove the plastic connector and swap it over to your wires. Make sure you install the wires back in the same spot on the new connector. If junkyards are far away or they don't have what you need, a good 2 part epoxy stuffed in the backside of the connector will certainly hold it together for the rest of time without issue, it's just not reversible.

 

Ok I'm back. So I looked it up and it's a 90980-10711. Which is readily available. I don't see any pigtails. But you can get the connector with new terminals and rubber seals. Don't worry about the color not matching. I promise you that's the correct part #. If you order it and it ends up being wrong I'll pay you back full price + shipping(+ whatever it costs to ship it to me).

https://www.google.com/search?q=9098...QgIKAM&dpr=1.5

You might also find the 1991-2005 Toyota Wire Harness Repair Manual useful.

 

If the clip or connector tab are broke silicone let fully cure will hold and be able to be removed .

Till you get around to fixing it correct which in my case is several years later.

 

Mudhippy, you are the man!!!! LOL Thanks for the info!!! I would'nt have even thought of trying to find the connector. I did run across some that were like $50 with the pigtails. Not gonna spend that much for a connector. So thanks again!!