door loom faults removing pin terminals to use new lengths of cable and terminal

[stupot11]

only my second post on here so forgive me if i not done things correct

well hope someone can help me with my current problems with galaxy mk2 ghia,read many
post regarding the door wire repairs on here but cannot find the information i require .having owned my galaxy for 18 years i have in the past repired the door looms as decribed in many post by rejoing and adding stright connectors and shrink tubing  to broken wires .well the time has come where i can no longer do this as the wires have broken off at the top of the terminals,saw the harness repair kit and thought just the thing remove terminal pins insert new terminal pins cut and join wire job done .trouble is i cannot remove terminal pins from old door plug tried hours and making tools as some have done on youtube to remove pins but still can not get pins out.from looking many hours on internet i believe these pins/terminals to be junior power timer terminals and micro power terminals.
can any body help and describe or show how to guide to do this
kit i boughthttps://www.ebay.co.uk/itm/235680383285?_skw=galaxy+door+harness&itmmeta=01JA0X6SJFMJ13BS4P1PE5N129&hash=item36dfa54135:g:VUwAAOSwtXFmrcNY&itmprp=enc%3AAQAJAAAA8HoV3kP08IDx%2BKZ9MfhVJKkgdse53dfXARjjjDgduAjclvoFdbtkh73%2FrBHKCkDlSNb6CkHRL8iOTLS8a%2Fy8LFz%2Brwja%2BYznopmnmi6n%2BLuwPR8MygsHfpMegShlD7YeEeeaxU6jkdEj6jFCMjL9LLrtmSiUJ6bMoPe%2F3nfQ3FJ7pLk%2BLgZ176b03yXslRKuj7lqDI9YcFffZitZ%2FW%2BGN71kZacvffgt28H2o75RxCPrVqb728WwlwEqNxrMhiYX4RjfvwXihrujn5rkMrMysG2axGg9En%2FbYKMpGlWQoyAu0EvHjFPGI%2Bx8IkzaTFUv1A%3D%3D%7Ctkp%3ABk9SR6qZm53QZA

like i say just cant figure out how to remove the pins hopefully some one can help this is on the rear doors but going to have to do same on drivers door pretty soon too.
thanks

[Chrispb]

It's a shame they don't supply the release keys with the wiring kit, I bought a set of keys that were supposed to fit every type of plug going but not the galaxy also the colours don't match.
As a last resort and with the age of car I think I would do away with the plug and socket and just solder each wire separately.

[stupot11]

hi thanks for reply well ive found more information regarding these connectors/looms etc from searching and translatingmany many manyy pages on web.
from info gathered the front driver and passenger plugs have a purple tab in the center which you move to one side to free the terminals for exchange/replacing
the teriminals are larger size junior power timer terminals male
and smaller size micro timer terminals and cable sizes 16awg/20awg/26awg/
so in theroy should be able to make new sections of loom and insert into plug and crimp into place

unfortunately still cant find any info on the rear plugs and these do not have purple bit to open up so the terminals can be replaced

will keep updating post if find anything further
will be buying silicon wire and terminals and replacing sections on my front doors as found cracked wires in there too febi kit for front door repair currently £55 im sure wire terminals and patience will be cheaper.
owned car 18years and like to keep her stock with genuine parts when able to

[Chrispb]

Just looked at two old looms I have an indeed have the purple peg that moves slightly with a click but doesn't seem to release anything but can plainly see two slots on each terminal so either a forked key or two separate keys to release each wire/pin like these.
https://www.ebay.co.uk/itm/322439614272?fits=Car+Make%3AVW&_skw=vw+wiiring+multi+plug+pin+release+keys&itmmeta=01JA9258SQCP1J3KCFDGQEB5NB&hash=item4b12e60f40:g:vu0AAOSwhlZYt9Ac&itmprp=enc%3AAQAJAAABAHoV3kP08IDx%2BKZ9MfhVJKn122LzINelEX3SrJpzpNkIjNsIRrUihkFVFirwloUxNKL8PKF%2FNSIDciUWtMRJ3yN2nSvRGsSh0PENgfXLWkHqyYNQwgFsIAg3MkShtLw4SOfFOVRkBBFxPOnpFc0nUutj2mxYb7yXExAiVNpu1H2wQGs8WBexqqEieX8u6xCU%2BxgoOnMhUfthjog%2BferRGpb3pX%2FYZzWRCRC9PoWMC%2B%2BTIRm%2FjSd96c5odfeA761S7tmbNzfeQwDNYERk5LnW7%2FcygzaxbuD1wkhxEEcirKXuklucgzrpA%2BaYTkjuOz8ZnT%2FsPVKKqY9PNjl%2FUnSuiNk%3D%7Ctkp%3ABk9SR_yMlaLSZA

[stupot11]

seen post on a foreign site where once the purple stub is moved to unlock position the whole section with puple clip slides up wires so pins can be exposed and removed ,
i ve made my own tools like tweezers to remove the pins from a stainless steel insert from a old wiper blade filed down to correct sizes.
on the rear door plugs there is no purple tab to unlock pins.
small micro pins -
you just insert tool(tweezers )either side of pin push in and pull terminal out from back of plug with wire
larger pins are slightly different insert tool (tweezers)into slot at side of flat pin and the other slot thats 2/3mm to the side push down and pinterminal can be removed these terminal pins are offset

larger pins/terminals for rear doorloom plug are vw 904 886.01   
small pins/terminals are micro timer teerminal 000979132E

i have ordered all the parts i need so once received will attempt repair and post on here how to/results

[Solentview]

I wonder whether stupot11 could get some photos of the job and his tools, and show us what he has done.

[stupot11]

hi yes will post pictures etc of repairs to loom and description of methods used once all parts received .
just waiting to get well enough following illness and dry days as no garage to work in

i intend remove the door looms completely from the doors so can work on them indoors and more comfortable and practical.

having no luck finding the offsett junior timer terminal pins only in germany and the company will not post to uk,so next step maybe to vw parts dept and enquire with part number and see if they can help

[Chrispb]

Will be interesting to see the results, the only thing I remember that slides off (after depressing the 3 lugs simultaneously) is the locking ring that keeps the plug locked in to the socket and also keeps the rubber gaiter in place.

[mushdy]

Hi stupot11, did you have any luck with terminals? I might be able to help...

[stupot11]

hi there mushy ,yes all sorted quite easy job in the end hardest bit getting door connector back together in small gap between door and body
 all terminals in front looms are micro power timer terminals (thin wires) with the exception of 3 that are junior power terminals (for the thicker power wires which are the most commonly broken.
will post a full description of what i did with photos once i can understand how to add photos to post
turned out only the thicker wires in drivers and front passengers door was broken and needed replacement.

if anybody can help me to understand how to attach photos i will be very grateful

[Chrispb]

In the quick reply box under your last post click the preview button, this will open the click and drag files, you can write a post and add photo's saved on your device, make sure everything looks OK before you click post as I think there is only a limited time to edit your own posts.

[stupot11]

hi chrispb
thank you very much for info ill get photos and post up soon

[stupot11]

Hi there sorry the delay in adding this post ,description of replacement of door loom wire and terminals,will try my best to remember everything that i did , tools and parts required
Front door looms:
 Larger size terminal pins are junior power terminals and 16awg silicone wire                                smaller size  pins are micro power timer terminals and 20awg silicone wire
Tools :pin remover bought tool from ebay 2 sizes around £6 best option or make your own from old wiper blade stainless steel insert bend and filed to shape .crimping pliers to suit terminal

Remove door card plenty of videos to show this available on internet and remove foam inner protection by pulling and cutting thru black sealer very sticky with Stanley knife blade and peel awy half way down door  (put back in place when reassembling)


Remove door plug connector by turning slowly with pump pliers on the castellated grip being carefull not to remove the other part from the car body,need to slightly close door to remove plug


Remove cable clips ties etc from inside door to give as much slack on loom as possible and pull loom thru door removing plastic guard at same time by squeezing clips in either side of it.
On door plug slightly push in the 3 clips holding the castletated connector and slide slightly forward to be able to remove the rubber door gaitor and access the wires


To remove pins slide purple tab to other side to free of terminal pin lock insert correct size pin removal tool into slots either side of terminal to be removed and push a little fiddly but pull wire from other side of plug and it should come free.
Do 1 terminal pin at a time leaving pin out tool in slots so you do not mi terminals into wrong slots
Crimp correct size terminal onto correct size wire and insert into slot and remove pin out tool make sure terminal pin is located securely  cut wire to correct length to remove broken wire and crimp on heat shrink straight crimp connector and heat heat connector to seal joint repeat for any broken wires   



Reassemble in reverse be very carefull assembling door connector make sure the connector is in the correct place you can feel as put together before you turn the castellated nut clockwise to fasten .

hopefully this help out if you have broken wires in your door loom