Electrical Failure - what to do

[Ted Borck <tborck@domain.elided>]

> Date: Tue, 11 May 1999 12:17:13 -0700
> From: Al Evitts <albert@domain.elided>
> Subject: Electrical Failure
> 
> Help:  Bought a new 75 Scout over the weekend.  While flushing out the
> road tar the PO had for oil I was leaving the engine run.  About 10
> minutes later the engine just shut off as tho the key was turned off.  I
> now have;  no lights no accessories no gauge movement,no start, no power
> at coil with switch on.  I have power at the battery connection on the
> starter.and no further.  No blown fuses.  Any body got any ideas as to
> what the check?   TIA

Al,

Chances are (do I hear Johnny Mathis?), you have a case of
intermittent passenger side bulkhead conectors.

What to do:

Wiggle them while another tries cranking the engine - if you then get
power it is the connectors. It seems the plastic tabs holding the
connnectors together - fatigue, due to age and oxidation, and no
longer provide a secure electrical connnection.

Then:	take out the glove box (if you don't have air conditioning,
you may be able to get the cab side of the bulkhead connectors with
out taking out the glove box.

:remove the connectors, clean the male and female electrical
connectors with a brass brush.

:examine the male and female 12 gauge (light blue wire) alternator
connectors.

:is the plastic around the 12 gauge connectors showing any signs of
heat?  If so email me and I'll show you a quick and easy work around
that worked for years in my Scout II.

:spray some electrical contact cleaner (plastic safe) on the
electrical contacts.

:drill a 7/32 - 1/4 inch hole at the 3:00 and 9:00 positions on either
side of both bulkhead connectors on the passenger side.

:get zip ties of sufficent length (I fastened two together for each
connector) to run through the holes in the firewall and between the
wires (on either side) entering the connectors.

:loop the zip ties on each bulkhead connector together, and snug them
down to clamp the bulkhead connectors together.

:seal the new zip tie holes with appropriate silicon sealer.

Hope this helps, as this is how I solved my bulkhead
connection problems in 1990.

Ted Borck	tborck@domain.elided