Bulkhead connector problem [Archive] - Chevelle Tech

: Bulkhead connector problem


68454SS
May 15th, 07, 6:18 PM
I have been having some intemittent problems lately, specifically the entire electrical/ignition system dies randomly. When it goes, it's everything, lights, radio, ignition, everything. I figured this had to be a problem possibly at the main junction behind the fusebox to affect the entire car like that. I got the inner fender pulled down and was able to get at the bulkhead connector, and the wires look to be in ok condition, but there is a hole in the middle of it where I think the bolt is supposed to be? Does anyone have a picture of what this is supposed to look like? Does it have to be removed from the inside of the car, or does it just 'pull out' if the bolt is missing? Would that cause a problem similiar to what I am experiencing?

Jim Streib
May 15th, 07, 6:43 PM
On my 70's car there is a center bolt on the bulkhead connector. It threads into an insert on the other half of the bulkhead connector which on my cars is directly behind the fuse block.

http://hometown.aol.com/krystaldesigns/pageA13.html

On mine there is a bolt that has a retaining clip on it to where it cannot fall out coming therough from the engine side of the bulkhead connector.

I have seen some bulkhead connectors where the wires look fine (even after you dig out the tar like sealant) but sometimes the male and female connectors become loose. A good indication after cleaning the connectors is looking for discoloration.

Jim

bigskycountry
May 16th, 07, 12:37 AM
Just had a similiar situation with my Chevelle. Driving down the road and nothing,..... lights,starter,radio,nothing. Juice from the starter to the bulkhead, but no juice at the fuse box under the dash in the car. The main power wire had come dislodged between the two halves, where you would pull out the bolt and seperate them. The tester will tell you where the problem is.You need the replace the bolt, however the bolt does not sound like your problem at this point,and yes the bulkhead will pull apart with some patience.Sounds like you will find your problem there. You may need to rig a new plug in lead, that is clean,no rust, corrosion, or discoloration, and guaranteed not to pull out in the future.

undee70ss
May 16th, 07, 3:34 AM
Would that cause a problem similiar to what I am experiencing?

Have you checked the easy things first? First disconnect battery - cable when working on the main wiring. Check small wire from battery + to junction block, and the 2 larger wires at the horn relay buss bar. Disconnect and clean both the connection at the battery and junction block, make sure they are clean, corrosion free and tight. Check the 2 larger wires at the horn relay buss bar, make sure they are clean, corrosion free and tight. If any of these connections have been rewired with those cheap crimp on connectors, remove them and use crimp and solder connectors. If original (and still there) also check the fusible links, look for signs of melting, pull on it some. If it feels like rubberband, it may be almost burned in two. If all that checks out, then check bulkhead connector. Loosen bolt and seperate the 2 halfs. Look at the terminal that has the larger 12g red. Any signs of burning, arcing or discoloration, replace the terminals with new ones.

http://www.chevelles.com/showroom/data/500/medium/Original_Chevy_system.jpg