Truck Parts and Service | Heavy Duty Trucking, Aftermarket, Service Info
Issue link: https://read.dmtmag.com/i/811350
12 Tech Updates C onstant coupling and uncoupling of a J560 7-way connection will wear down the connection over time until eventually the connection needs to be replaced. To replace a plug without purchasing an entirely new cable assembly, Phillips Indus- tries recommends the following process: 1. Dismantle the housing of the old plug by removing the screw and wedge/cable clamp at the back of the plug and the screw on the side of the housing. Slide the housing back to expose the cable and plug insert. 2. Remove the insert from the cable by backing off/unscrewing the set screws, or cutting the wires as close to the back of the insert as possible, depending on the type of plug insert being removed. Dispose/recycle the old insert. If the wires are removed from the insert by removal of screws, rather than cutting, AND the wires are free from corrosion, it may be possible to skip steps 3-6 below. (Note: If replacing the entire plug, remove old housing and slide the new housing on before proceeding.) 3. To allow for more working length where needed, if absolutely necessary, carefully cut and remove as little cable jacketing as possible to expose the internal wiring. 4. If needed, cut the individual wires to length for placement in the back of the insert. The ground (white) and the auxiliary/ABS (blue) wire should be a tad bit shorter to accommodate for the slight protrusion of those connections on the back of the insert. (Note: If any corrosion is present on the wires, cut the wires back until all corrosion is removed.) 5. If needed, strip each wire approximately 1/4 in. (Optional: Solder the ends of each wire to make inserting them into the back of the insert cleaner and easier.) 6. Partially unscrew each screw on the back of the plug insert. Insert the wires referencing the corresponding colors for each connection on the back of the insert. Tighten the screws. 7. Slide the housing back into place and replace the wedge and screws to hold the cable and housing together in place. (Op- tional: Apply di-electric grease to the pins at the front of the plug to help prevent corrosion.) T R U C K P A R T S & S E R V I C E | A p r i l 2 0 1 7 REPLACING A J560 7-WAY PLUG