I think I have a question that hasn't come up in the last 20 years on this forum. My 4WD stopped working on my 2001 Jimmy. I decided to look at the transfer case actuator connector to look for corrosion. The pins look good but I think the wires leading to the connector are corroded, thin, and 1 may have broken just ahead of the connector. How do I replace the connector? I can cut the wires and strip them again, but I need a connector to plug into the actuator.

 

If you are not able to find the specific connector, buy a full connector set and replace both ends.

 

The pins or terminals within the connector are removable, just takes care, patience, small screwdriver to do so. Then you can repair the wires, and if needed, replace the terminal(s), re-insert back into the connector body/shell.

 

It plugs directly into the switch on the transfer case, so I can't change both ends.

 

Have you ever done this? I can't re-use the terminals so where do you get such tiny terminals?