1991 940 electrical connectors
 

Due to corrosion I need a new connector for the front sidelight for the 940
This is the connector on the end of the wiring harness.. It will need to be soldered to connect to the harness.
Is this available anywhere, new or second hand?
Thanks
Ian Fife

volvo have the terminals and housings , don't solder though its bad practice as with any moving in the wind the wire will crack where the solder meets the copper wire. Crimping is always best in the automotive trade unless there is no possibility of movement .

Thanks Clan. I don't usually have much success trying Volvo dealers. Is there anyone in the UK that you could recommend for me to try for this part?

Ian Fife

Can you post a photo? I might have something in the garage/spares stash.

Many thanks for the offer, but it is all back together now with some slightly dodgy connections, and I really don't want to disturb it.
The connector has two wires running to two female connectors inside a black housing. The housing has three holes arranged on the threes sides of an imaginary square, one of which is unused of course. I do have several of the white plastic bulb holders ( three male pin type which fit this, these are very robust, hence I have a collection.
It's the wiring going into the black female connector on the end of the loom which has corroded away and needed a tricky repair.

Ian Fife

P.s. I can of course post pictures of the white plastic bulb holders which the piece I am needing connects with, if that would help?

Ian Fife

The best/cheapest place I’ve found for the Volvo female connectors is Aliexpress. For example,

https://www.aliexpress.com/item/32707342320.html

They only seem to do the two-pin housings, but it’s rare for the original plastic housing to be beyond reuse. I prefer the pre-made tails which you can then join onto the original cable with heat-shrink crimp butt connectors.

Aliexpress send products direct from China and elsewhere so delivery can take several weeks.

This is the bulb holder for the front sidelight. I am looking for the black plug on the wiring harness which fits this plug. Anyone have one please?

Ian F

still available from volvo and the terminals

OK, thanks. My local Volvo dealers are not very helpful

Can you suggest a source please?

Ian F

Your task sorts the parts men out from the parts boys....
whoever does look up the parts will need to study the parts list for the correct shape terminals and plug. But who are we to say... I would try the dealer near you first see how they get on.

The parts manager at Keith Price volvo at Abergavenny is probably the man to ask as he goes out of his way to help and has over 40 years experience with volvo a very rare thing now.

Thanks Clan. I will try and track it down.

Ian F

I'll check my garage as I've got quite a few bits from 940's and deffo some light fittings

As I said last month, you can get them very cheaply from AliExpress, although watch delivery charges and minimum order numbers.

Pictures from the listing I linked to. If you want to remake the end of your existing cable go for the ones like picture 1. I prefer to get the ones in the second picture and join the wires in heat-shrink butt connectors. You just reuse the outer casing from the existing plug rather than the generic two-pin casing they are supplied with.

Thanks everyone. Luke R came up with a good used one which I now have. So all sorted.

Ian F

heya, so i actually created an account to reply to this as it's so rare that a thread that's helpful doesn't have a last reply from about a decade ago, lol

anyway, went to change my sidelight housings to clear, the bulb holder things were jammed in the old one so i unlatched them, bought new ones, went to put in the new ones with bulbs and the end of one of the sidelight wires just snapped off the connector. ive seen the links to the aliexpress ones above and think they would probably fit (they dont look the same as the ones on the car but i can always shave down some plastic) but unfortunately they wouldnt arrive for a week, and my MOT is on tuesday :// so does anyone happen to have a connector i can crimp into the cars wiring that would connect to either of these that i can try and get before then, or a suggestion as to what i can try to bodge it until the aliexpress one arrives? if i hold the wire against it it lights up but electric tape doesnt seem to hold it tight enough
cheers

Try a blob of solder on the terminal and a blob of solder on the wire, then melt the two together. I did this successfully on mine before I got a replacement terminal. You may need flux to get the solder to stick at the terminal.

Ian F

If you can't get a replacement connector then get a couple of bullet connectors and crimp them on to your loom then stick them on the pins. You can pot it with silicone if you wanted a waterproof longer term solution, you may need to cut back some of the wiring and make a small extension loom if the wires are corroded or broke too far away.

You don’t use the whole connector. The two-pin outer casing is wrong for this application. You use the crimp terminal and the rubber protective sleeve and install them in your original plastic socket body. They are an exact fit and a good permanent solution to this problem.