How to Get a Brake Controller Harness Connector Through a Small Hole for Installation

Question:

I am upgrading from a Voyager to a P3 controller. The voyager has a pigtail connecting it to the under dash factory socket. The pigtail wiring goes through a small hole in the dash the socket will not pass through this hole. How can I remove the old harness without cutting it? Do the wires in the plastic fitting pull out? I tried this but I dont want to break anything. I dont know if the pigtail can be removed from the voyager unit either. I just bought the new pigtail for the P3 unit. It connects great but now I have the same problem in reverse. I want to pass the wires through the old hole but the fittings on the ends are too big and I dont want to enlarge the holes.I think there is something about the pigtail fittings that I dont know. The wires must somehow pull out of the fittings to allow the wire to pass through holes and then replaced? I have a 1996 dodge ram 2500.

asked by: Brian D

Expert Reply:

The easiest way to get that connector through the hole would be the reverse of how you got the Voyager harness through the hole. You will need to cut the wires and then pass the wire end of the connector through the hole and then reconnect the wires using solder or butt-end connectors.

I wouldn't recommend removing the wires from the connector and then reinstalling them as they can be kind of difficult to release and if you were to get the wiring of the connector wrong you could damage the controller.

expert reply by: Jameson C