96 2.3l air temp sensor

[hutchlovesford]

The air temp sensor poped out while driving and melted. I was able to find a new sensor but the plug was also ruined and i cant find it annnywhere. Every parts store i go to say that theres none in their inventory. any suggestions? i know you can make your own sensor pretty easily, but im at a loss for the plug.

 

[Earl43P]

Is this a two pin plug?

If so, you can make do with a typical spade (socket) terminal.
Use a pair of sharp dykes and cut one half of the spade terminal away, leaving you with a single spring to grip the pin. Do the same for the other wire/pin, but cut the opposite side so they will nest nicely in the old connector's space.

Once you've settled on a nice fit, go ahead and cut off the old plug while noting which wire went where on the sensor.

Remove the crappy plastic insulator from your sockets.
Put a length of heat shrink tubing over the wire.
Solder the wires to the sockets even after you crimp them together.
Shrink the tubing over most of the socket.
Apply dielectric grease then install sockets to sensor.
Plug up the old connector's void with grey RTV or clear silicone sealant. Both of these are easy to remove but give an effective seal.


Here are a couple terminals like what I'm talking about. They are too big to fit "as is", so you cut them.

http://www.amazon.com/3M-Insulated-Female-Disconnect-Terminals/dp/B003IADEAW/?tag=959media-20

http://www.amazon.com/Pico-Electrical-Insulated-Connect-Volkswagon/dp/B00030CXA2/?tag=959media-20