Intermittent operation: DB9 and DB25 connector replacement
- Hi Mike,
Thanks for your reply! Your suggestion could work if the extension cable were weather-proof. The problem I've had, after talking at length with several different electronic supply places, is finding weather-proof connectors.
I've had this "intermittent operation" problem for several years, so the car was just sitting while I "tried this, tried that" to no avail. Very frustrating as otherwise it's a great car!
I've been following posts for many years and have corrected pretty much everything with no success until I used contact cleaner and compressed air on the DB25. I had already replaced the DB9 previously but with "bare connectors" now covered with electrical tape (not a proper, professional solution). From previous posts I had the impression the DB9 was the connector responsible for the symptoms (shutting down, only able to "crawl" ever so slowly, then ready to go within minutes - sometimes longer). But a subsequent post mentioned the DB25, contact cleaner, etc.
It turned out the contact cleaner on the DB25 eliminated the problem.....for a few thousand miles, anyway, then it came back. Cleaning the connector again solved the problem but for less (and less) time each time. Apparently my Force was in NJ originally, so there's a bit of rust here and there and the outside of the DB25 has a bit of what looks like "salt water corrosion". The inside doesn't look bad from a visual POV, but I can't argue with the fact that the contact cleaner worked....at least for a while. Most recently I cleaned it again and applied dielectric grease but that hasn't made much of a difference. So the only logical conclusion I've come to is to replace the connectors.
Any suggestions on solutions, especially where to order new weatherproof connectors, would be much appreciated. So far the best solution seems to be the weatherproof "hanging style" female (so I could swap controllers down the road if necessary) and a "panel mount style" male connector mounted in a box. Since the new DB9 with elec tape should be redone more "professionally", I think a small box with both the DB9 and DB25 male connectors in it would be best. Your question about shielding could be a critical piece of the puzzle too, so I'm hoping someone in the group can address that (ie, do these cables/connectors need to be shielded?).
Thanks for the feedback Mike!
- Ray Darby
96' Force EV
83' Grumman EV
----- Original Message -----
Sent: Friday, September 24, 2010 1:21 PM
Subject: [solectria_ev] Re: DB9 and DB25 connector replacement solution for Force
I'm not sure how the cables terminate inside the "boxes" but another way to get a free hanging male/female is to simply buy a good m/f extension cable of suitable length and cut it in half. This would mean replacing the entire wire and not just the end. I guess you could do a splice if you don't want to open the "boxes".
The nice thing about doing it this way is that manufactures own ends are generally nicely matched.
I'm thinking the Solectria wires are not shielded anyone know if they are?
Strange that all 4 connectors on your car need replacing.
--- In email@example.com, "Ray Darby" <raydarby@...> wrote:
> Feedback and/or alternative suggestions much appreciated! -
> Like many Force owners my DB9 & DB25 (free hanging) controller connectors need to be replaced. I can't find "free hanging" male and female, however, so the tech at www.digikey.com suggested a male hanging style and female panel mount style connector. The males would be on the controller side and the females could be panel mounted in a small electronic box (enclosure) for weatherproofing. Here are the part numbers for the male connectors; the corresponding female panel mount are listed under "mating products" near the bottom of each page -
> 25 pin -
> 9 pin -
> - Ray Darby
> 96' Force EV
> 83' Grumman EV
> [Non-text portions of this message have been removed]
[Non-text portions of this message have been removed]