firewall wire plug removal

[rossboss]

What is the best and probably the only way to remove and reinstall the firewall wire plug for the headlights horn and voltage regulator. It's the big plug that's right in front of the driver. I'd like to do it without breaking anything, seems to be in pretty tight.

[padresag]

patiently. they interlock on the inside and I think that it was the use of 2 screwdrivers and a few words from under the dash. they are a lot easier to put back in as they can be made softer(like when new) by putting in the microwave for a short period of time(short means short- repeat until softer to use) andperhaps a touch of vaseline and do it now while it is soft
ron
I did explain it once with a picture but can't seem to find it. a hair drier or a heat gun may be helpful in taking it apart

[padresag]

here are a couple of pictures of them apart


ron

[rossboss]

Does the plug need to push into the engine compartment to be removed or does it push under the dash.

[padresag]

looking at the last photo should tell you that the plug itself comes out towards the dash as it has all of the harness still attached.
ron
do not put the plug in the microwave unless you take all of the metal clips out. just the outer ring really needs to be plyable

[earl84]

Softening in the microwave, good idea. I got a replacement and it made it very easy to put in. The 50 year old one was very hard and impossible to replace, wish I had known the microwave trick.

[rossboss]

By looking at the pieces I would think that the plastic harness end should be pulled into the engine compartment add the rubber grommet and then push it into the firewall hole.

[chevyrestoguy]

I just went through this recently. Do yourself a HUGE favor and buy a new firewall grommet set. The original grommets will turn rock-hard after 50 years, and they will not flex at all. Once I got my new grommets, I sprayed them with a little WD-40 (any silicone spray will work) and popped them in from the engine bay side. Make sure that the larger flange of the grommet is on the engine bay side, flush to the firewall. The grommet will have a tapered side on the opposite end, and that's the side that goes in first. When it came time to install the harnesses, I installed them from the inside of the truck by lubing the connector and pushing it through. It doesn't require much force, and just be sure not to push it in too far, or you'll pop the grommet out of the firewall.