Brian, can you describe the proper technique you found after disassembling the connector?
Thanks!
Russ
It is very hard to describe. I wish I had taken pictures of the connector with the end off. The advice from VP is to not take these apart and I am sure that if you do, they will be annoyed at the least if you mess up one of the connectors.
However I did not find them to be self destructing when I did take the end off of one to see how it was made inside. If you have other pins inserted when you do this, you must be careful to keep them in their positions because the part that holds them in place is what you are removing to get a look at the latching parts.
As best as I can remember, you need to keep the release pin as straight as possible, keep it as close to the crimped on power connector as possible so that the release pin makes it way between the crimped on power connector and the release catch. If you look at one of the crimped on power connectors, it it has a "U" channel on one side with a notch where the locking tab snaps into when the power connector is inserted into the housing. The release pin must make its way down that "U" channel and get in between the power connector and the locking tab to make it release.
If you have to push hard or the release pin tool goes in too far, it won't work properly. It also helps to push the connector all the way up into the housing before inserting the release pin tool to give the catch room to move without binding on the power connector.
I also found that the shape of the end of the release pin tool needs to be worked on. I think mine came with a rounded end on it. I filed mine to have a slanted end on it and put the long side toward the power connector each time and this made it easier for the release pin tool to get between the catch and the power connector.
Keep in mind that all of this is from memory and the older I get the more the memory fails!
Clear as mud?
I should have taken one apart and made a video. Sorry!