desertspeed
Adventurer
I posted this in another forum, but I thought folks here may find some of the info useful as well.
I have been researching different connectors as I have been re-wiring parts of my truck over the past couple of years, and I thought I would share this info as a reference guide to the different kinds of multi-pin connectors that are out there. Hopefully this will save some research time for anyone who is doing some wiring, from light bars to removable dashes, to complete re-wires.
This is certainly not meant to cover every type of connector available, but the most commonly used connectors in off-road with an eye towards availability and economy- Weatherpack, Metripack, Deutch, and Mil-spec or Cannon type connectors. Not all of these would be appropriate for use in a high-end race car, but work fine for most vehicles.
I will go into more detail on each connector below, but I typically use the following connectors:
2-3 terminals, less than 20 amps- Weatherpack
2-3 terminals, 20-30 amps- Metripack 280 Series or Deutch DTP
2-12 terminals, less than 13 amps- Deutch DT
10-60 terminals, 7.5-23 amps- Amphenol Mil-Spec Circular Plugs
I have provided links to where I have ordered connectors/pins/tools, etc., but there are lots of other options on where to buy.
Delphi Weatherpack
Number of terminals: 1, 2, 3, 4, 5, 6, or 22
Terminal Wire Size: 22-18, 16-14, 12 AWG
Max Pin Rating: 20 amps
Pros- Inexpensive, water sealed, crimping tool is relatively inexpensive
Cons- connectors are not very compact in larger pin counts, pins are rolled and not solid, limited to 20a max.
Uses: LED tail lights, interior lights, anything with 2-3 pins and less than 20 amps. Once you get above 3 pins, Deutch connectors are much smaller. If you need 2-3 pins and more than 20 amps, go with a Metripack connector.
Ordering: http://www.waytekwire.com/products/20/Weather-Pack-Connectors/
You need a male connector (Tower), female connector (Shroud), male terminal, female terminal, and cable seal. Female terminals are used with 'Tower' housings and male terminals are used with 'Shroud' housings.
Crimping Tool: http://www.waytekwire.com/item/533/CRIMPER-SEALED-METRI-PACK/ $22.50
You can buy more expensive crimpers that will crimp both the wire and the cable seal in one step, but these work fine.
Delphi Metripack
150 Series- 2, 3, or 4 terminals, 22-18 AWG, 14 amps max (there is no reason to use these over Weatherpack connectors, so I won't go into any more detail).
280 Series-
Number of terminals: 1, 2, 3, or 5
Terminal Wire Size: 16-12 AWG
Max Pin Rating: 30 amps
Pros- Inexpensive, water sealed, crimping tool is relatively inexpensive (same tool as Weatherpack), can handle up to 30 amps
Cons- 3 or 5 pin connectors are bulky
Uses: LED light bars, fans, fuel pumps, race radios
Info: http://whiteproducts.com/index.shtml
Ordering: http://www.waytekwire.com/products/19/Metri-Pack-Connectors/
You need a male connector, female connector, male terminal, female terminal, TPA locks, and cable seals (same as Weatherpack seals).
Crimping Tool: http://www.waytekwire.com/item/533/CRIMPER-SEALED-METRI-PACK/ $22.50
You can buy more expensive crimpers that will crimp both the wire and the cable seal in one step, but these work fine.
480 Series- 2 or 3 terminals, 12-10 AWG, 42 amps max.
630 Series- 2 or 3 terminals, 12-10 AWG, 46 amps max.
The 480 and 630 series are similar to the 280 series, but are rated for a higher amp load- I can't think of anything on a vehicle that would have that high of a draw, except maybe an amp.
Deutch/Amphenol DTM
Number of terminals: 2, 3, 4, 6, 8, or 12
Terminal Wire Size: 22-16 AWG
Pin Size: 20
Max Pin Rating: 7.5 amps
Pros- high quality, connectors are compact for number of terminals, water sealed, solid pins
Cons- crimping tool is more expensive
Uses: LED tail lights, interior lights, electronics, anything with 2-12 pins and less than 7.5 amps.
Ordering: http://www.waytekwire.com/products/1497/Deutsch-DTM-Compatible-Amphenol-ATM-Connectors/ , http://www.prowireusa.com/c-76-deutsch-dtm-connector-kits.aspx , or eBay.
You need a male connector (plug), female connector (receptacle), male terminal (pin), female terminal (socket), and wedgelocks. I find it easiest to order connector kits, which come complete with connectors, pins, wedgelocks, etc.
Crimping Tool: HDT 48-00 http://www.prowireusa.com/p-435-hdt-48-00-hand-crimp-tool.aspx $237.50
Please note that this crimping tool will also work for the Mil-Spec connectors below.
Deutch DT/Amphenol AT
Number of terminals: 2, 3, 4, 6, 8, or 12
Terminal Wire Size: 20-14 AWG
Pin Size: 16
Max Pin Rating: 13 amps
Pros- high quality, connectors are compact for number of terminals, water sealed, solid pins
Cons- crimping tool is more expensive
Uses: LED tail lights, interior lights, electronics, switch panels, anything with 2-12 pins and less than 13 amps.
Ordering: http://www.waytekwire.com/products/13/Deutsch-DT-Compatible-AT-Connectors/ , http://www.prowireusa.com/c-19-deutsch-dt-connector-kits.aspx , or eBay.
You need a male connector (plug), female connector (receptacle), male terminal (pin), female terminal (socket), and wedgelocks. I find it easiest to order connector kits, which come complete with connectors, pins, wedgelocks, etc.
Crimping Tool: HDT 48-00 http://www.prowireusa.com/p-435-hdt-48-00-hand-crimp-tool.aspx $237.50
Please note that this crimping tool will also work for the Mil-Spec connectors below.
Deutch DTP/Amphenol ATP
Number of terminals: 2 or 4
Terminal Wire Size: 14-10 AWG
Pin Size: 12
Max Pin Rating: 25 amps
Pros- high quality, connectors are compact for number of terminals, water sealed, solid pins
Cons- crimping tool is more expensive
Uses: Fuel pumps, fans, LED light bars, race radios. Similar applications as Metripack 280 series, but more expensive.
Ordering: http://www.waytekwire.com/products/24/Deutsch-DTP-Compatible-ATP-Connectors/ , http://www.prowireusa.com/c-77-deutsch-dtp-connector-kits.aspx , or eBay.
You need a male connector (plug), female connector (receptacle), male terminal (pin), female terminal (socket), and wedgelocks. I find it easiest to order connector kits, which come complete with connectors, pins, wedgelocks, etc.
Crimping Tool: HDT 48-00 http://www.prowireusa.com/p-435-hdt-48-00-hand-crimp-tool.aspx $237.50
Please note that this crimping tool will also work for the Mil-Spec connectors below.
Milspec, or “Cannon” Connectors
There are numerous companies that make multi-pin circular connectors, and many of them have special crimping tools that only work with their terminals and can get very expensive. After researching a bunch of them and talking with Joey Davitian from ProWire (no, I do not work for ProWire and I am not getting any commission from them, but I have ordered from them many times and they are extremely knowledgeable and helpful), I decided to use Amphenol MIL-26482 Series 2 connectors- they are very common in motorsports applications, they come in a huge variety of configurations, and they use the same pins and crimping tool as the Deutch connectors.
Number of terminals: 3-61, in various configurations
Pin Sizes:
20: 24-20 AWG, max 7.5 amps
16: 20-16 AWG, max 13 amps
12: 14-12 AWG, max 23 amps
Ordering these connectors can be very confusing, and get very expensive. You will probably only need a few of them on your truck at most, so I found it easiest to figure out how many terminals/wire size/amps I need for each plug and just call up ProWire to order a complete connector. They can cost $150 and up, but they should last indefinitely and can be re-used if needed by just ordering new pins/sockets, which can be bought in bulk.
Here is a link to the Amphenol Catalog- http://www.tntc.com/news/Amphenol MS3470.pdf
If you want to figure out the nomenclature/numbering system yourself, here is a chart:
For example, for the plug that goes through my rear firewall for all of the wires to the rear of my truck (16 wires), I ordered MS3474L20-16P and MS3476L20-16S
MS3474 (receptacle) L (aluminum shell w/ electroless nickel finish) 20 (shell size) – 16 (# of terminals) P (pins)
MS3476 (straight plug), L (aluminum shell w/ electroless nickel finish) 20 (shell size) – 16 (# of terminals) S (sockets).
I have been researching different connectors as I have been re-wiring parts of my truck over the past couple of years, and I thought I would share this info as a reference guide to the different kinds of multi-pin connectors that are out there. Hopefully this will save some research time for anyone who is doing some wiring, from light bars to removable dashes, to complete re-wires.
This is certainly not meant to cover every type of connector available, but the most commonly used connectors in off-road with an eye towards availability and economy- Weatherpack, Metripack, Deutch, and Mil-spec or Cannon type connectors. Not all of these would be appropriate for use in a high-end race car, but work fine for most vehicles.
I will go into more detail on each connector below, but I typically use the following connectors:
2-3 terminals, less than 20 amps- Weatherpack
2-3 terminals, 20-30 amps- Metripack 280 Series or Deutch DTP
2-12 terminals, less than 13 amps- Deutch DT
10-60 terminals, 7.5-23 amps- Amphenol Mil-Spec Circular Plugs
I have provided links to where I have ordered connectors/pins/tools, etc., but there are lots of other options on where to buy.
Delphi Weatherpack
Number of terminals: 1, 2, 3, 4, 5, 6, or 22
Terminal Wire Size: 22-18, 16-14, 12 AWG
Max Pin Rating: 20 amps
Pros- Inexpensive, water sealed, crimping tool is relatively inexpensive
Cons- connectors are not very compact in larger pin counts, pins are rolled and not solid, limited to 20a max.
Uses: LED tail lights, interior lights, anything with 2-3 pins and less than 20 amps. Once you get above 3 pins, Deutch connectors are much smaller. If you need 2-3 pins and more than 20 amps, go with a Metripack connector.
Ordering: http://www.waytekwire.com/products/20/Weather-Pack-Connectors/
You need a male connector (Tower), female connector (Shroud), male terminal, female terminal, and cable seal. Female terminals are used with 'Tower' housings and male terminals are used with 'Shroud' housings.
Crimping Tool: http://www.waytekwire.com/item/533/CRIMPER-SEALED-METRI-PACK/ $22.50
You can buy more expensive crimpers that will crimp both the wire and the cable seal in one step, but these work fine.
Delphi Metripack
150 Series- 2, 3, or 4 terminals, 22-18 AWG, 14 amps max (there is no reason to use these over Weatherpack connectors, so I won't go into any more detail).
280 Series-
Number of terminals: 1, 2, 3, or 5
Terminal Wire Size: 16-12 AWG
Max Pin Rating: 30 amps
Pros- Inexpensive, water sealed, crimping tool is relatively inexpensive (same tool as Weatherpack), can handle up to 30 amps
Cons- 3 or 5 pin connectors are bulky
Uses: LED light bars, fans, fuel pumps, race radios
Info: http://whiteproducts.com/index.shtml
Ordering: http://www.waytekwire.com/products/19/Metri-Pack-Connectors/
You need a male connector, female connector, male terminal, female terminal, TPA locks, and cable seals (same as Weatherpack seals).
Crimping Tool: http://www.waytekwire.com/item/533/CRIMPER-SEALED-METRI-PACK/ $22.50
You can buy more expensive crimpers that will crimp both the wire and the cable seal in one step, but these work fine.
480 Series- 2 or 3 terminals, 12-10 AWG, 42 amps max.
630 Series- 2 or 3 terminals, 12-10 AWG, 46 amps max.
The 480 and 630 series are similar to the 280 series, but are rated for a higher amp load- I can't think of anything on a vehicle that would have that high of a draw, except maybe an amp.
Deutch/Amphenol DTM
Number of terminals: 2, 3, 4, 6, 8, or 12
Terminal Wire Size: 22-16 AWG
Pin Size: 20
Max Pin Rating: 7.5 amps
Pros- high quality, connectors are compact for number of terminals, water sealed, solid pins
Cons- crimping tool is more expensive
Uses: LED tail lights, interior lights, electronics, anything with 2-12 pins and less than 7.5 amps.
Ordering: http://www.waytekwire.com/products/1497/Deutsch-DTM-Compatible-Amphenol-ATM-Connectors/ , http://www.prowireusa.com/c-76-deutsch-dtm-connector-kits.aspx , or eBay.
You need a male connector (plug), female connector (receptacle), male terminal (pin), female terminal (socket), and wedgelocks. I find it easiest to order connector kits, which come complete with connectors, pins, wedgelocks, etc.
Crimping Tool: HDT 48-00 http://www.prowireusa.com/p-435-hdt-48-00-hand-crimp-tool.aspx $237.50
Please note that this crimping tool will also work for the Mil-Spec connectors below.
Deutch DT/Amphenol AT
Number of terminals: 2, 3, 4, 6, 8, or 12
Terminal Wire Size: 20-14 AWG
Pin Size: 16
Max Pin Rating: 13 amps
Pros- high quality, connectors are compact for number of terminals, water sealed, solid pins
Cons- crimping tool is more expensive
Uses: LED tail lights, interior lights, electronics, switch panels, anything with 2-12 pins and less than 13 amps.
Ordering: http://www.waytekwire.com/products/13/Deutsch-DT-Compatible-AT-Connectors/ , http://www.prowireusa.com/c-19-deutsch-dt-connector-kits.aspx , or eBay.
You need a male connector (plug), female connector (receptacle), male terminal (pin), female terminal (socket), and wedgelocks. I find it easiest to order connector kits, which come complete with connectors, pins, wedgelocks, etc.
Crimping Tool: HDT 48-00 http://www.prowireusa.com/p-435-hdt-48-00-hand-crimp-tool.aspx $237.50
Please note that this crimping tool will also work for the Mil-Spec connectors below.
Deutch DTP/Amphenol ATP
Number of terminals: 2 or 4
Terminal Wire Size: 14-10 AWG
Pin Size: 12
Max Pin Rating: 25 amps
Pros- high quality, connectors are compact for number of terminals, water sealed, solid pins
Cons- crimping tool is more expensive
Uses: Fuel pumps, fans, LED light bars, race radios. Similar applications as Metripack 280 series, but more expensive.
Ordering: http://www.waytekwire.com/products/24/Deutsch-DTP-Compatible-ATP-Connectors/ , http://www.prowireusa.com/c-77-deutsch-dtp-connector-kits.aspx , or eBay.
You need a male connector (plug), female connector (receptacle), male terminal (pin), female terminal (socket), and wedgelocks. I find it easiest to order connector kits, which come complete with connectors, pins, wedgelocks, etc.
Crimping Tool: HDT 48-00 http://www.prowireusa.com/p-435-hdt-48-00-hand-crimp-tool.aspx $237.50
Please note that this crimping tool will also work for the Mil-Spec connectors below.
Milspec, or “Cannon” Connectors
There are numerous companies that make multi-pin circular connectors, and many of them have special crimping tools that only work with their terminals and can get very expensive. After researching a bunch of them and talking with Joey Davitian from ProWire (no, I do not work for ProWire and I am not getting any commission from them, but I have ordered from them many times and they are extremely knowledgeable and helpful), I decided to use Amphenol MIL-26482 Series 2 connectors- they are very common in motorsports applications, they come in a huge variety of configurations, and they use the same pins and crimping tool as the Deutch connectors.
Number of terminals: 3-61, in various configurations
Pin Sizes:
20: 24-20 AWG, max 7.5 amps
16: 20-16 AWG, max 13 amps
12: 14-12 AWG, max 23 amps
Ordering these connectors can be very confusing, and get very expensive. You will probably only need a few of them on your truck at most, so I found it easiest to figure out how many terminals/wire size/amps I need for each plug and just call up ProWire to order a complete connector. They can cost $150 and up, but they should last indefinitely and can be re-used if needed by just ordering new pins/sockets, which can be bought in bulk.
Here is a link to the Amphenol Catalog- http://www.tntc.com/news/Amphenol MS3470.pdf
If you want to figure out the nomenclature/numbering system yourself, here is a chart:
For example, for the plug that goes through my rear firewall for all of the wires to the rear of my truck (16 wires), I ordered MS3474L20-16P and MS3476L20-16S
MS3474 (receptacle) L (aluminum shell w/ electroless nickel finish) 20 (shell size) – 16 (# of terminals) P (pins)
MS3476 (straight plug), L (aluminum shell w/ electroless nickel finish) 20 (shell size) – 16 (# of terminals) S (sockets).
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