Use this guide anytime you need to repair a wire harness, repair a connector, or you want to plug into an existing harness in your rig. You can also cut off wires at a harness, and solder them on at the connector for a factory look if you want to run something different to an existing harness (like the grey wire mod).
First, you will either need to save, or open this file. Thanks to NCTTORA for uploading this file!
http://ncttora.com/fsm/Toyota Wiring Repair Manual.pdf
For reference, a “plug” is the plastic connector by itself, a “connector” is the metal leads that slip into the pluf, and a “wire harness” is the plug and the connectors assembled together.
First, I will go over how to replace a broken plug. I’ve had this happen a couple times, most recently when I fixed a coolant leak in my block, and the plug for the knock sensor shattered in my hands as I pulled it off of the knock sensor. The heat deteriorated the plastic and made it brittle. You can order any of these parts at your local Toyota dealer, or Toyota of Dallas. TOD is much much cheaper, especially if you’re buying a lot...
On your plug, there should be 5 numbers printed on it, usually on the back. These numbers are the last 5 digits of the part number. The first 5 numbers of the part number for the plug, is ALWAYS 90980-. Here are a couple pictures of some plugs, a male, and a female. For reference, the white plugs are male plugs for a Tacoma Lisense plate, the grey female plug is for a turn signal harness for a Tacoma.
![Image]()
![Image]()
The part numbers for the white plugs are 90980-11168, the part number for the grey plug is 90980-11020. Make sense so far?
You will then need to remove the connectors from the plug. You will need to fabricate (or buy) the tool to unclip the connector from the plug. The dimensions are printed in the manual. I made mine out of a pop rivet, using a grinder. You may be able to use a teeny flat blade screwdriver as well.
![Image]()
First, you will need to free the lock on the plug. Some plugs are a block on the side that you lift up and out of the way. Some locks are located in the front. Usually, if there isn’t something to unclip in the front, it’s located on the side of the plug. Look closely on the male plug, you’ll see the tab on the sideof the inside that you pry away with the pick. The female plug is easy to spot.
![Image]()
![Image]()
Insert your pry tool of your choosing, and free the lock
![Image]()
I find it easier to completely remove the lock from the plug. If you look back at the picture of the male plug, you’ll spot the clip that holds the connector in place. You need to insert the tool between the connector and the clip, to free it from the wire. I find it simple to insert, then pry up so that it forces the clip to open.
![Image]()
![Image]()
At the same time you are freeing the clip, pull on the wire from the back of the plug. You shouldn’t need to force anything, if you’re freed the clip, the wire should slip out with ease. Before removing the wire, note which slot the connector slides into (1,2,3,4...)
Here is a picture of the wires out of the plug.
![Image]()
![Image]()
All you need to do now is grab your new plug, and slip the wire into place. Slip the connector in the same spot. It only goes in one way, if it does not easily slide in, do not force it, spin the connector and try again. Once it slips in, you’ll hear a faint click, and you’ll be faced with this:
![Image]()
![Image]()
Then push the lock back into place. It will click when fully seated.
There you have it, you have just repaired a broken plug! You can also use the wire removing technique to change polatiry on plugs, or move wires around on plugs.
First, you will either need to save, or open this file. Thanks to NCTTORA for uploading this file!
http://ncttora.com/fsm/Toyota Wiring Repair Manual.pdf
For reference, a “plug” is the plastic connector by itself, a “connector” is the metal leads that slip into the pluf, and a “wire harness” is the plug and the connectors assembled together.
First, I will go over how to replace a broken plug. I’ve had this happen a couple times, most recently when I fixed a coolant leak in my block, and the plug for the knock sensor shattered in my hands as I pulled it off of the knock sensor. The heat deteriorated the plastic and made it brittle. You can order any of these parts at your local Toyota dealer, or Toyota of Dallas. TOD is much much cheaper, especially if you’re buying a lot...
On your plug, there should be 5 numbers printed on it, usually on the back. These numbers are the last 5 digits of the part number. The first 5 numbers of the part number for the plug, is ALWAYS 90980-. Here are a couple pictures of some plugs, a male, and a female. For reference, the white plugs are male plugs for a Tacoma Lisense plate, the grey female plug is for a turn signal harness for a Tacoma.
The part numbers for the white plugs are 90980-11168, the part number for the grey plug is 90980-11020. Make sense so far?
You will then need to remove the connectors from the plug. You will need to fabricate (or buy) the tool to unclip the connector from the plug. The dimensions are printed in the manual. I made mine out of a pop rivet, using a grinder. You may be able to use a teeny flat blade screwdriver as well.
First, you will need to free the lock on the plug. Some plugs are a block on the side that you lift up and out of the way. Some locks are located in the front. Usually, if there isn’t something to unclip in the front, it’s located on the side of the plug. Look closely on the male plug, you’ll see the tab on the sideof the inside that you pry away with the pick. The female plug is easy to spot.
Insert your pry tool of your choosing, and free the lock
I find it easier to completely remove the lock from the plug. If you look back at the picture of the male plug, you’ll spot the clip that holds the connector in place. You need to insert the tool between the connector and the clip, to free it from the wire. I find it simple to insert, then pry up so that it forces the clip to open.
At the same time you are freeing the clip, pull on the wire from the back of the plug. You shouldn’t need to force anything, if you’re freed the clip, the wire should slip out with ease. Before removing the wire, note which slot the connector slides into (1,2,3,4...)
Here is a picture of the wires out of the plug.
All you need to do now is grab your new plug, and slip the wire into place. Slip the connector in the same spot. It only goes in one way, if it does not easily slide in, do not force it, spin the connector and try again. Once it slips in, you’ll hear a faint click, and you’ll be faced with this:
Then push the lock back into place. It will click when fully seated.
There you have it, you have just repaired a broken plug! You can also use the wire removing technique to change polatiry on plugs, or move wires around on plugs.
