I know the culprit, but need a tip on the solution.

[DKing]

If you've spent any time under your 944 dash with the wiring cover off, you've seen this picture.



See that fat red wire on the green harness? That's the main power wire to the ignition switch. He goes from the switch up to this green harness that connects to the bottom of the relay panel here. Mine is a poor connection. It works 99.7% of the time, but when it failed, it took me days to figure out that the pin has a bit of play in the harness and needs to be pushed in a bit. My dad drove the car once and gave me a call wondering why he was stranded without power. I told him to give that wire a nudge and he was right back on the road. It hasn't failed since, but I'm pretty worried about it coming loose while on the freeway or something. Are replacement pins available, or what would you suggest?

Cheers,
Dan

[v2rocket_aka944]

small adel clamp around the wire, screwed into that little hole/tab below it on the green plug?

[IdahoDoug]

Always a good idea to identify what year and model 944 you are asking about.

[DKing]

Great idea!

BTW, it's the '86 (85.5) NA listed in my garage.

[Jfrahm]

Figure 8 double ziptie trick.

[djnolan]

if the terminal is being pushed out of the plug, what if you pull the terminal out of the plug, bend the part that catches on the plug to catch better, and reinsert it.

Or If it is staying in place but the relay connection is loose, then use a pin removal tool to free it from the plug, and gently squeeze the terminals with a small pliers to tighten them up and reinsert.

Although the double zip tie method seems very promising due to the proximity of the little green tab.

[TibetanT]

First and foremost, the Plugs for the Electrical box are locked into place by a sliding arm on the underside of the box.

I would check that first before doing any other of the suggestions above.

Also, check the relay and fuse on the top of the box to ensure it seats well. This can cause the plug you are showing us to "push" the big red wire out of its seat.

You may need to replace the entire box if the locking mechanism is broken or does not lock these plugs in place.

I have two (2) replacement fuse boxes that are fairly new; less than 6,000 miles on the car I took them from if you need this.

Also, this is VERY IMPORTANT…when working on the Electrical system on these cars, unhook the Battery Negative cable!!

Note: You can remove the box from the top by unscrewing the two (2) large bolts holding this together and then make sure all of the plugs are seated properly before locking it down.

Hope this helps you.

[DannoXYZ]

Eh? All that's a lot of work if all you need is to bend out the catch-finger on terminal so it stays inside connector.