90160930900 "Wood screw" plug connector

[Jonny042]

I ordered a set of Beru plug wires that are dismantling themselves at the plug connector. Options seem limited if you want to maintain a "stock" look and use all the factory plug wire holders etc. so I want to keep the stock diameter wires - so Clewett, Magnacore, etc. are all out of the question.

I'm considering ordering qty 6 of part #90160930900 made by Beru. Am I throwing good money after bad, thinking that maybe the replacement connectors available separately are somehow better made that the crap that came with the plug wire kit?

Has anyone purchased and used these? There is also a 90160930901 by Beru that seems slightly different so I'm hoping I can score the older version that might be made somewhere on-shore.....

I am also open to other options that use the wood screw type connector at the plug end for the wire, but it seems Beru is the only option.

[Lyle O]

At one time you could purchase just the wires from Beru (via Pelican) and use the stock connectors. You simply unscrewed the connector off the wire (as the wire had the threaded part well-crimped to the wire and insulation). For some reason this is not offered any longer (at least not on Pelican). I did this, as my connectors were in great shape, but the wires were not. Doing it this way has lasted me well for 5 years or so. It is a pretty simple system and works well, as long as the crimp of the screw-on part to the wire is good (and you can easily check this before installation), and you don't over-torque the connector-to-wire screw-on interface. Perhaps you can find just the wires elsewhere and use your existing connectors.

[Jonny042]

The newer style used the M3 crimp-on connector for the wire end (SC and later) whereas the early style up to 1977 I think, or pre metal braid, at least, used a screw that looks like a wood screw to bore into the plug wire and make contact with the conductor.

I do also have a used set of SC plug receptacles that might be a good candidate for what you are suggesting. Do you know if there is a source for a small quantity of the M3 crimp-on connectors?

(EDIT - found the crimps, wonder what tool would be best used to crimp them?

[Flynt]

Beru ZAZ4 Ignition Wire Tool
Tool - Pricey!

https://www.beruparts.com/main.sc
Everything else. It's also at Kingsborne. They're great.

[Jonny042]

Well I'm happy to report I was able to save the connectors I have:

1. Spend an hour or so with an inspection camera and various implements to fish the remains of one connector out of my cylinder head.

2. Took 5 of them apart (well, 3 fell apart on their own). Last one wouldn't budge so I guess it passes torture test.

3.uncoiled the spring on the last turn just enough so that it won't fall out of the connector should they happen to fall apart again.

4. tweaked retainer clip so the connector is a bit easier to clip on and off a plug.

5. epoxy the whole works back together and re-install after measuring resistance on each.

Not happy about having to mess around with stuff that's junk, but I feel the fix is permanent and they will last years.

[Jonny042]

Originally Posted by Jonny042

Not happy about having to mess around with stuff that's junk, but I feel the fix is permanent and they will last years.

WRONG!! They fell apart again. They lasted 4 or 5 heat cycles and 150km.

JUNK. Going to buy Clewetts.