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Old 03-21-2021, 06:17 AM   #1
russcc
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Default '40 Headlight harness bullet connectors

I as there a good way to get what appears to be copper bullet connectors to pull apart without damaging the wire and insulation that hook the '40 headlight switch pigtails to the wiring harness. ?
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Old 03-21-2021, 06:36 AM   #2
HDowse
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Default Re: '40 Headlight harness bullet connectors

I’ve never had much luck pulling apart the original connectors. At a minimum the hardened rubber flakes and breaks off but at least then you have a shot at using two pairs of needle nose pliers to pull the units apart. Most often there's corrosion within the sleeve and on the bullets that needs to be cleaned off. I toss the old sleeve out. Then I dig into my stash of new connectors and refit the wires. I suspect most of the vendors carry the various sizes of connectors but being nearby, I got mine from Joe's Antique Auto.
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Old 03-21-2021, 10:25 AM   #3
19Fordy
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Default Re: '40 Headlight harness bullet connectors

Put a drop or two of WD 40 on the connector and let it soak for 5 min before pulling them apart. No doubt the rubber will be too brittle to save.

Then solder on modern bullet connectors that really are tight and cover the "repair" with new replacement original stock rubber covers. Practice on a scrap piece of wire first to make sure it looks authentic. Use heat shrink over the connectors BEFORE installing the rubber covers.

Last edited by 19Fordy; 03-21-2021 at 10:52 AM.
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Old 03-21-2021, 06:33 PM   #4
russcc
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Default Re: '40 Headlight harness bullet connectors

I have already removed the old brittle rubber cover, that's how I could see that the bullet connector sleeve was a copper color. Once I get them apart, and ready to rewire I use heat shrink tube over all the electrical terminals. Not after original looking, just good electrical performance.
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Old 03-22-2021, 09:07 AM   #5
rotorwrench
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Default Re: '40 Headlight harness bullet connectors

I made a tool that can be forced into the gap of the round female socket for some of the old ford terminal blocks. I haven't tried it on the single or double pin rubber covered connectors but it should be easy to spread the socket gap after the rubber cover is gone. The tool works well on the bakelite or plastic type terminal blocks.

If a person doesn't spread the socket a bit, those old bullets will be a devil to try and separate. I had no luck doing that until I made the tool.
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Old 03-22-2021, 03:19 PM   #6
Ggmac
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Default Re: '40 Headlight harness bullet connectors

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Quote:
Originally Posted by russcc View Post
I have already removed the old brittle rubber cover, that's how I could see that the bullet connector sleeve was a copper color. Once I get them apart, and ready to rewire I use heat shrink tube over all the electrical terminals. Not after original looking, just good electrical performance.
The copper ones I just removed from a 41 , had a small stake making pulling apart very hard . I inserted a screwdriver blade and spread the connector a little . Some connectors had enough space for the screwdriver, others didnt . If i need to save the connector , I soldered back together with 2 layers of heat shrink to look like the rubber cover .
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