Why Did Mopar Make The Bulkhead Connector Less Reliable?

[threewood]

There is a big diference between the bulkhead connector in my 1962 Belvedere and my 1969 GTX. You would think Chrysler would have made improvements in parts, not downgrades. Everyone knows the issues with the black and red wire going through the bulkhead connector.

My 1962 connections for these two wires that traverse from the alt to the ammeter and back out to the starter relay utilize a bolted connection like a buss. In order to remove the connector, both little bolts have to be removed. These are as it came, no modifications.

The 1969 bulkhead connections for these two wires are straight up Packard 56 connectors which get loose and corrode.

When did Chrysler move away from the earlier connections and why?

Pics of my 1962 bulkhead connection...

 

[snakeoil24]

They hired dumb electrical engineers that didn't know what they where doing!

 

[Daliant]

Probably wasn't the engineers, I'd blame the bean counters. The later style is easier to put together on the assembly line, precious seconds saved times each vehicle equals $$$.
Heavy duty/taxi/police models had separate harness for the charging system though the firewall bypassing the bulkhead connector thus eliminating the trouble spot.

 

[Billccm]

I'd suspect the change was for ease of manufacturing. Back in those days everyone was looking to shave three seconds off the assembly process.

 

[threewood]

Probably wasn't the engineers, I'd blame the bean counters. The later style is easier to put together on the assembly line, precious seconds saved times each vehicle equals $$$.
Heavy duty/taxi/police models had separate harness for the charging system though the firewall bypassing the bulkhead connector thus eliminating the trouble spot.

That is as close to an admission from Chrysler that their normal connectors suck. Probably saved .02 cents a car and 10 seconds on the assembly line. Good trade off on cars that had a tendency to burn to the ground lol.

 

[rumblefish360]

Seriously!!!!
LMAO!!!!

 

[khryslerkid]

They only expected the car to last 5 years or 100,000 miles.

 

[Billccm]

As an engineer who spent 28 years in the semiconductor industry I can tell you cost always wins over quality. I've supported auto industry applications, and with Honda being the exception, cost will be the winner in the application. Even Toyota will take a $0.03 savings on a lesser component.

 

[threewood]

They only expected the car to last 5 years or 100,000 miles.

But everything was rebuildable. The bodies rusted away before everything else stopped working. Most old components are still beter than new parts.

 

[Dennis H]

Mine lasted over 40 years. When it failed, the contact cleaner ran black for an extended time indicating it had probably been on since installed at Lynch Road in May of 1969.

 

[snakeoil24]

They hired dumb electrical engineers that didn't know what they where doing!

Agree it always is the bean counters!

 

[Mike67]

That is as close to an admission from Chrysler that their normal connectors suck. Probably saved .02 cents a car and 10 seconds on the assembly line. Good trade off on cars that had a tendency to burn to the ground lol.

Built in repeat customers....make something that people love despite the defects or issues...make it last just long enough as not to piss people off and you have a customer for life. You can just about bank on when they will be coming back for a new purchase...

 

[WP29440SE]

mine is still working great after 45 years

 

[threewood]

mine is still working great after 45 years

The one I pictured above is original. I pulled the wiring to paint the engine compartment and it was in great shape. Still have the ammeter hooked up too. Now my 69 was burned through, melted connectors, as well as the extra harness I had. I had to bypass them for peace of mind.

 

[moparnation74]

The one I pictured above is original. I pulled the wiring to paint the engine compartment and it was in great shape. Still have the ammeter hooked up too. Now my 69 was burned through, melted connectors, as well as the extra harness I had. I had to bypass them for peace of mind.

It was a great design and should have never been changed.....but the wonderful pennies per thousands of vehicles won...

 

[lewtot184]

could the engineers have dreamed we'd still be driving these cars 50yrs later? people we're trading in every 2-4yrs back then. a 60's car back then with 75,000 miles was probably shot. I still use the factory wiring concept (new harnesses) and never had an issue. maybe i'm lucky or maybe i'm just judicious about keeping wires and connections clean and in good condition,.....?

 

[Ranger16]

mine is still working great after 45 years

Ditto - 49 years....................and counting.

 

[73sechgr]

GREAT SUBJECT FOR OLD MOPARS,ENGINEERS DO WHAT THERE TOLD BY THE BEAN COUNTERS A LITTLE HERE A LITTLE CUTBACKS THERE,BURN TO THE GROUND COMMENT IS WILD BUT SOME DID DO JUST THAT,,,,WHEN YOU SEE SOLID OLD MOPARS THAT ARE NICE BUT RUST HOLES IN FIREWALL BEWARE NEVER SEEN MANY GM SWISS CHEESE FIREWALLS ON OTHER WISE RUST FREE CARS,,I AM RETIRED INSPECTOR MAINTENANCE AND ENGINEERING FROM AIRLINE INDUSTRY,WE USE TO JOKE ALL DOUGLASS AND AIRBUSS ENGINEERS GOT FIRED FROM BOEING AKA SAME AS FIRED AUTO ENGINEERS FROM GOOD COMPANY TO BAD COMPANY,FILL IN THE BLANKS AS YOUR OPINION DICTATES,,,GUYS AT FORD GOT FIRED FROM AMC OR HOWEVER YOU PREFER ..............................................