2002 O2 sensor connector & wire repair

[dvTJ]

Happy Saturday folks!

I have a broken Bank 1 Sensor 2 wire. Unfortunately it snapped right at the vehicle side connector. I actually started this project trying to get the sensor off until I realized that wasn't the issue. I don't have any soldering equipment and haven't soldered before. I know these bundled in with other O2 related wires. Can these be spliced in with a new connector with wires, or is it solder and/or replace the entire harness? I have haven't removed much of the harness conduit to see what connects to what from end to end.

 

[Chris]

Use some wire terminal tools such as these:
https://www.amazon.com/Lisle-57750-Wire-Terminal-Tool/dp/B007WQQHA2/?tag=wranglerorg-20

You'll be able to remove the terminals from the connect and re-use them. That's exactly what I'd do in this situation.

Get the terminals out of the connector, remove the wires from them, and then crimp them onto the new wires. I have those exact tools and they've come in handy more times than I can count for situations just like this.

 

[dvTJ]

Use some wire terminal tools such as these:
https://www.amazon.com/Lisle-57750-Wire-Terminal-Tool/dp/B007WQQHA2/?tag=wranglerorg-20

You'll be able to remove the terminals from the connect and re-use them. That's exactly what I'd do in this situation.

Get the terminals out of the connector, remove the wires from them, and then crimp them onto the new wires. I have those exact tools and they've come in handy more times than I can count for situations just like this.

Oh wow. I didn't realize these existed. Thank you! I will be adding to cart now. As far as the new wires I guess that's where I'm still searching. I don't think I have enough existing to crimp onto the old terminals but we'll see.

 

[Chris]

Oh wow. I didn't realize these existed. Thank you! I will be adding to cart now. As far as the new wires I guess that's where I'm still searching. I don't think I have enough existing to crimp onto the old terminals but we'll see.

Those tools are invaluable. I bought a set over a decade ago and find myself using them all the time. They make removing wire terminals a breeze.

Even if you can't reuse those terminals it would be easy to find replacements. They're just simple blade terminals such as these:

https://www.amazon.com/Twidec-Elect...n-Insulated/dp/B0CXSS8R91/?tag=wranglerorg-20

Just have to make sure you buy ones that are meant for the proper wire gauge.