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Discussion Starter #1
I have three questions concerning the mounting of the fuse block / bulkhead to the inside of firewall and then the attachment of the engine and front light wiring harnesses to the bulkhead on the engine side.

1) The connector plugs on the ends of the engine and front light wiring harnesses fit into each other and then both are attached to the bulkhead with one bolt. My question is....what does that bolt thread into? Whatever was on the backside of my bulkhead is gone. When I spread the fuseblock and bulkhead apart, all I see on the back of the bulkhead is the round hole in the plastic for the bolt to go through and nothing else. I would have thought there would be some kind of "captured" nut back there. (See the first two photos)

2) The third photo is from the AIM showing the attachment of the fuse block / bulkhead to the firewall. In View-A, it shows sealant to be applied but I am not sure to where. First off, what kind of sealer would that be? And does it go on the entire foam gasket to seal the gasket to the inside of of the firewall and then help seal the wiring harness connectors to the gasket? When I took this apart, I didn't see any evidence of any kind of sealer.

3) And lastly, the two long screws that attach the fuse block / bulkhead to the firewall. They came with sealer on the threads After having been threaded in once already, part of that sealer is gone. If I just replace the missing sealer with strip caulk, will that seal just as well?

Thanks.....Dave







 

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Dave
Question 1. Yes there should be a sort of rivnut there for it to grab on to.

This is the best picture I could find quickly with Google. Rear side of the connector


Question 2 - Dielectric grease was used to seal out moisture on the engine bay side of the bulkhead connector.

Question 3 - The firewall side I think was sealed with a type of dumb-dumb but strip caulk can be substituted.
 

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Pretty sure you can find something usable at the big box store in the fasteners boxes to grab the screw. Maybe just a thin nut and some crazy or gorilla glue.

It might also be in the AMK catalog but you have to order 30 buck worth of parts to do an order direct. SS396 - Ground Up stocks a ton of AMK so they might have it.

Or try calling Lectric Limited, AAW and also MH electric fabricators - http://www.wiringharness.com/ and see if they sell it alone.
 

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Another picture from the front side this time.

 

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Discussion Starter #5
Brian, thanks for hunting up those pictures. They help a lot!

I don't know how I could have lost that nut. It had to have been there when I took it apart a few years ago. I'll have to look in my box of "unidentified" nuts and bolts. At least now I have an idea what I'm looking for. If I can't come up with, I'll rig something that will work.

I'll have to admit to being a bit of a dumbbell when it comes to dielectric grease. Are you supposed to apply it directly onto contacts....or just seal any place water could get in and get to the contacts?

Dave
 

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Well its a sort of limited use type of thing so you won;t have too many in the box to try.

Dielectric grease conducts insulates and prevents moisture for penetrating. It can be applied to spark plug heads so the rubber boot of the wire won't stick to the porcelain of the plug so the wire can be easily removed for service. This is an example of it conducting and preventing moisture.

Since it could lead to arcing by its conductive properties you do not coat the individual connector pins of the bulkhead connector with it. You use it to seal the connection from outside moisture. I run a bead around the outer perimeter of the connection on the gasket - the new one you made. This will prevent water from getting under the connector.
 

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Here DG is used to seal the outside of the connections. I forgot about this.
 

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Discussion Starter #11
Sorry it took me so long to get back to this post. I took care of the missing nut on the back side of the bulkhead. I got a T-nut, drilled three holes in the flange of the T-nut, and then put screws through flange and into the bulkhead to hold it in place.

To address Victor's question about the dielectric grease on the engine and front light wiring harness connectors that attach to the bulkhead, I believe the dielectric grease you see on the wires where they enter the connector is applied from the outside just to keep water from getting in. I don't believe it is being squished out from the inside.

I am still wondering about the sealant that is shown in the AIM on the scan that I attached earlier. According to what I see, after the bulkhead is in place and protruding through the firewall, the bulkhead connectors are masked off and then a sealant sprayed from the engine side of the firewall. I am still wondering what kind of spray-able sealer that is and what is actually suppose to seal?

Thanks....Dave





 

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Very nice MacGyver repair. What part did you use?
 

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Discussion Starter #13
The T-nut looked like the picture below. I found it at a local electronics surplus house where they have all kinds of odds and ends besides electronics. They have all kinds of fasteners. It is the same place I found the foam to make a new fuse block to firewall seal. I had to shorten the threaded part just a little bit and drill the holes in the flange.

Dave

 

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:thumbsup:
 
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