Corroded molex connectors

EbikeFu

EbikeFu

Member
Local time
6:57 PM
Joined
Dec 12, 2024
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42
Location
Florida, USA
I'm about to attempt to change MOST of the electrical connectors in my Engwe EP2 PRO because they are covered in corrosion and has recently started giving me throttle and motor communication errors. Looking at them in the connectors they are covered with the crystalline white stuff.

I'm going to pull the pins and see how bad the corrosion is. Must likely will have to replace the wire end so I should just cut them off but the depining set will be here in about 20 mins. I'm afraid because this is the first time I've ever done anything electrical. But in my mind the connectors are the weak link here. And the cheapest fix.
I do have a brand new controller coming at the end of the month so if it turns out that the controller is shot at least I'll have the connections cleaned up but, of course the molex connector assortment I ordered did not come with anything but molex connectors. I didn't know.
 
Also I have a replacement throttle coming tomorrow as well.

The replacement PAS sensor I ordered arrived yesterday so at the very least I can use the 72 piece depining kit to get the different wire colored connector it came with to at least line up with the colors coming off the old controller. Of course opening the box to install the pas sensor is what brought me to a standstill to begin with
 
1000002134.jpg
ive finally stripped the wires for the first connector. Yay!!
Is this the correct way to insert the wire in this pin?.

On mine the red section is already closed out of the box
The blue is the only place that exposed wire should be. (Mine are a little longer so I can snip them or bend them backwards)
Black is where the colored insulation portion of the wire will be

According to what I'm seeing on YouTube that's the correct orientation right?

But how are guys getting the pin loaded into the crimper? It feels like my boss tool just barely holds these small things in place and then as soon as anything touches it or the tension in my grip changes, it just falls to the floor. How do you get these to stay put long enough to crimp?
 
I would strip the wire the full length of those 3 wing clamps on the pin. You want the wire to be clamped by all three of those folding wing clamps. You dont want to crimp the insulation. Have the insulation butted against the clamp at the base of the pin.Those small pins don't feel like much in the crimper. Its hard to tell what is going on. Its best to get your hands just right on the crimper so you have as little movement as possible when its time to crimp. Take a picture of your pin crimper. I may be able to help a little more
 
Also, WD-40 has a great contact cleaner if there are some connections you want to try and salvage. Living near the sea has its own particular challenges.
Screenshot_20250105-070001_Chrome.jpg
 
I've had one more thought. If your worried about a wire running short, you should be able to depin it. I've done this on cars. There are a lot of videos on it. You unclip it with the key, pull out the pin, clean it all with the cleaner and then reinsert it. I've used this method on Jeep harness wires. If it doesn't work you are no worse off.
Screenshot_20250105-074125_Chrome.jpg
 
Annieolnie said:
I've had one more thought. If your worried about a wire running short, you should be able to depin it. I've done this on cars. There are a lot of videos on it. You unclip it with the key, pull out the pin, clean it all with the cleaner and then reinsert it. I've used this method on Jeep harness wires. If it doesn't work you are no worse off.View attachment 17911
Click to expand...
I did order this and it truly is a great value for the set. I took a break and ordered some pre crimped pigtails
SM Connectors Male Female Plugs Sockets https://a.co/d/7qWQoyn
And some of these to connect them
TICONN Solder Seal Wire Connectors https://a.co/d/cTw6xxr.
Those should be here tomorrow and hopefully I will be rolling again
 
Links to Amazon may include affiliate code. If you click on an Amazon link and make a purchase, this forum may earn a small commission.
So far I've only connected the PAS wires the way I think they should go using electric tape. I'll upload a pic in a second. When I turn on the bike there is a error 22 throttle issue. When I pedal nothing happened the first 2 times. The 3rd time the rear tire went into full speed and wouldn't stop until I turned the bike off.

This makes me think that the problem squarely is in the corroded connectors. Evidently, its the throttle that's causing my issue now.

I have the replacement here but just like the pas I have to do a little rewiring when my connectors get here later today.

From the looks of it I should be able to take off the male end from the throttle and replace it with a female connector. The colors already line up with the old throttle so that's good.

The pas is another thing though.
The controller had yellow black red from left to right with the pins facing down
Pas had red yellow black so I depinned it.
I connected the Yellowsto yellow and red to red.
That just left blue and black. is that right?
 
Should the pas have done anything when I turned the pedals even with error 22 on the screen?
I do remember that while the motor was wide open the error message was gone
 

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