Hi Tom,

Just wondering about the black connector... mine looks like a piece has been hacked off, and the retention clip is only present on one side. Are all ECU+ units like this, or was mine done like this because you didn't have enough of the correct connector? Not a big deal, just curious. I'll probably end up using the zip-tie fix just in case.

 

Try this

http://www.ecuplus.com/forums/viewto...highlight=#999

 

I think mine has the updated header with the retention clip, so I shouldn't need the tie wrap. I was just surprised to only see one clip, and not two. The header looks like it was cut with a Dremel tool to fit, thus losing one of the clips.

 

Matz - except for the first couple, all of the units I ship have the retention latches, and there are two latches. It sounds like yours was somehow broken in shipping. Did you get your ECU+ new?

Tom

 

Yes.

--Dan
Mach V

 

I also did a continuity check on all of the wires in the black and white connectors, and the red wire in Group A had no connection, so I'm assuming there was a bad crimp. No big deal, as I have those crimps in the office and I'll replace it tomorrow.

 

So I just pulled out the red wire from Group A that was failing the continuity test. Sure enough, it's a bad crimp. It looks like it was crimped with those crimpers that don't account for insulation! The rear pair of barbs was smashing the insulation. When I moved the crimp around with my DMM connected, I got an intermittent connection. I hope that this is a complete fluke, and that the rest of the header isn't crimped like this...

 

This sucks. I thought we had Hirose crimps here that would work, but they are the wrong size. Tom, I will probably figure out a way around this, but in the meantime, would you be able to provide me with the part # for the crimp, so I can order a bunch of replacements? Maybe also the part # for the header as well, so I can replace that at the same time. I can figure it out myself by browsing Digikey or Mouser, but I'd feel better if I just got the info directly from you.

The header doesn't look like it cracked in shipping, as the broken piece wasn't in the bag, and given the way it looks, I'd be surprised if it broke after assembly. I think it was a defective header that got put in for whatever reason.



Here's what the bad crimp looks like. See how the strain relief is crushing the insulation. The broken connection was caused by that. I got continuity after the strain relief only by bending the wire back and forth...

 

Matz -

Let's get both of these issues fixed. I'll PM you my address, and I'll pay shipping both ways. When you're paying $700 for something, it needs to be right - you shouldn't be crimping pins for me! The broken connector is very strange. I'm 100% confident it didn't leave here that way.

Tom

 

Ok, now I'm unbelievably frustrated. I made a temporary fix to the crimp, and put it back into the header. All was great until I had to remove slack from the wire. I held onto the zip tie and pulled on the red wire, and then 5 more wires came out of the header. Not a big deal, except that the light blue wire pulled out of the crimp! I'll post pics of what it looks like. The insulation on the blue wire is clearly crushed, just like the red wire. I think the main problem here is that the wire used has insulation that's just too thick. It certainly seems thick, given the wire gauge.

At this point, I'm going to cut all of the wires off of the header and solder directly to the main board. Tom, how will this affect my warranty?

 

Hi Tom,

Thank you very much for your responsiveness! I really don't have an issue crimping pins, as I do this stuff all of the time and it's really no big deal. I am still concerned about the insulation / crimp interface. I've tried to crimp wires like these before, and the crimp size is matched to the gauge of wire just fine, but because the insulation is so thick, the wire eventually fatigues and breaks after very, very few cycles. I'd feel a ton better just soldering to the main board.

Thank you!

 

Tom, I apologize for this -- I just found the other piece in the bag (I must be blind), so it definitely didn't leave your shop like that! Just wanted to clear that up.

 

Matz and I resolved this connector nonsense, and I've actually improved the quality of the connections across the board because of what he found. Matz - shall I put you in the satisfied customer column now?

Tom

 

Yeah! I didn't pull the crimps to do an inspection, but from our PMs, I'm sure you've got the technique down now. If my car is still running after the way I've been trying to force the cables around, things should be good.