Roush TVS Wire Connector De/Re-Pinning

OX1

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Used this thread here, which was excellent.

https://www.svtperformance.com/forums/threads/add-on-to-roush-tvs-installation-instructions.827645/

But one thing I could not find anywhere was really detailed explanation/pics about
getting electrical connectors apart and de/re-pinning. Not rocket science, but I
didn’t want to mess up a pin and be kicking myself for not spending the $150
for the VMP wiring harnesses.

First thing I recommend is one of these head mounted lights. Many times needed both hands and needed to see down inside connector.


20170513_084114.jpg



This is the tool I got, Lisle 57780 Terminal Tool for Ford, from Amazon for $13


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This is the end you want to use. It is the smallest of the single flat blades with a tapered end.


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Here is the TPS connector with backshell and rubber weather seal pulled back

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Remove red pin retainer. Can use angled pic to pull out. You can see small barbs on the top of next pic. These break pretty easy, but luckily, this retainer goes back in and stays, even if you broke off one of the little internal barbs.

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Orientation you need to hold connector. Note cavity above each pin.


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Insert the tool, with beveled edge of tool facing up, right above the pin. Ensure the tool is contacting top surface of pin. LIGHTLY slide in tool and you feel the lightest “click’ as the tool pushes plastic pin lock, upward.


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Pull wire out the back of connector. Note orientation of pin, it has a recess on the “top” where is mates with plastic pin lock in connector.


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Make sure when you are manipulating connector, you don’t bend wires in a position to force pin upwards (see pin all the way on right in next pic). I suspect it could damage plastic pin lock if one was too aggressive.


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Canister purge valve connector is a bit different. I could only get red pin retainer to pull upwards about 1/8 inch. It would not come off completely. I was able to remove pins without pin retainer removal.



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Tool insertion orientation.


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Again, note pin orientation for re-insertion (this is with new Roush supplied connector).


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Ensure wire colors are meeting up on both ends of connector while you are inserting.


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Last edited:

OX1

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Moving on to 3rd PCM connector. Bottom most connector with a “C” designation.
White pin retainer pulls off fairly easily


20170514_104853.jpg


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C58 is the wire you need to splice into and C36 is the new pin (shown already installed)

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Wire/Pin that needs to be spliced was Green with White stripe on my 14 GT.



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Again, note pin orientation. Hard to see with flash, but recess faces upwards to mate with plastic pin retention in main connector.


20170514_105639.jpg



The Brown wire with purple stripe needs to be inserted in a vacant pin location. Small plastic “covers” are molded into the connector and must be pushed out.


20170514_112713.jpg



I used a really small Allen wrench. It took a lot more force to punch out that small plastic piece than you would think it should. Don’t be shy.


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Brown wire inserted and Green/white wire soldered in.


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White Pin retainer pops back in place pretty easy.


20170514_113155.jpg



Did not bother with pics for MAF connector, as it is almost identical to TPS connector and can be re-pinned the same way.
 

Stangra

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Thanks Guys. Was surprised when I couldn't find it anywhere.....
Well... Thanks for putting it out there so that those of us that follow DO have a resource for this.

Thank you, thank you !!! Super helpful !!!
 

Stangra

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Messages
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Location
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--------------------------------------------------------------------------------------

Moving on to 3rd PCM connector. Bottom most connector with a “C” designation.
White pin retainer pulls off fairly easily


View attachment 1539782

View attachment 1539783

View attachment 1539784


C58 is the wire you need to splice into and C36 is the new pin (shown already installed)

View attachment 1539785


Wire/Pin that needs to be spliced was Green with White stripe on my 14 GT.



View attachment 1539786


View attachment 1539787


Again, note pin orientation. Hard to see with flash, but recess faces upwards to mate with plastic pin retention in main connector.


View attachment 1539788


The Brown wire with purple stripe needs to be inserted in a vacant pin location. Small plastic “covers” are molded into the connector and must be pushed out.


View attachment 1539789


I used a really small Allen wrench. It took a lot more force to punch out that small plastic piece than you would think it should. Don’t be shy.


View attachment 1539790


Brown wire inserted and Green/white wire soldered in.


View attachment 1539791


White Pin retainer pops back in place pretty easy.


View attachment 1539792


Did not bother with pics for MAF connector, as it is almost identical to TPS connector and can be re-pinned the same way.
PCM connector wire to be spliced (Green & White) is at location C56, not C58. Arrows in photos do indicate correct pin though
 

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