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Date:  7-15-2018
Number of Hours:  2.00
Manual Reference:  58-04
Brief Description:  Avionics power up (58-04)

Since I have the auto pilot panel controls, I have to change out the auto pilot harness with one that will work for these controls. I had already made the cut out earlier, but now I had to connect everything. Plus it also has to connect to the main switch panel, which means removing some wires (3 of them) and replacing them with wires from the new harness. This was a real challenge, the wires in the d-sub connector are pretty thick and the flimsy little tool that is supposed to be inserted just expands and doesn’t slide into the hole. I tried what seemed to be forever to get it to work. I watched several videos, but they all show how easily it works with thin wires. I finally got it to work but used a new tool that I hadn’t mangled up yet. The trick was to insert the wire into the extractor and pull the extractor back (away from the d-sub pins) until the wire is captured in the extractor. Then you can slide it down the wire until you get to the pin hole. Next I had to use my double set of magnifying glasses and some thin needle nose pliers to squeeze the extractor tip enough to get it into the very tiny hole. It worked with a little bit of pressure and was repeatable with the right technique. I removed the 3 wires and inserted the new wires…then I realized I forgot to slide the new wires under the shrink wrap, so I got to use the extractor again. I think I could make my own youtube video, except that I don’t want to mess with this anymore. That was the first challenge. The next was to remove the molex connector from under the panel. This attaches to the panel switch, but was connected to the old harness. I was supposed to remove it and put it on the new harness…easier said than done. Well the female connectors were in super tight and I could not get any extraction too to work. I could have just cut the wires and tossed the molex, but I ended up trying many different ideas. I noticed that Vans doesn’t offer the ES-00007 or ES-00008, so I went to Amazon and found what I needed.
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It works!

It works!

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that's a mess of wires

that's a mess of wires

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happy camper

happy camper

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