1996 Jeep Cherokee Sport, 4.0L, 352,000 miles. I am the only owner.

Problem: When I disconnect anything (oil sending unit electrical connector, coil wiring harness, O2 sensor connector, etc) it is very difficult to break loose and when I try to reconnect, the gasket (silicone gasket?) wants to bunch up and prevent full engagement of the locks. I noticed the gaskets have a right way and a wrong way at the oil sender and the crank position sender connections to the harness.

On what appears to be an O2 sensor plug on the passenger side top of engine compartment, (it is round, four prong, and looks like the connector for driver's side O2 connector near the oil pan) the connector would not go back together after opening and small application of dielectric grease to the pins. The grey silicone gasket was bunching up in the housing when I tried to connect it back together. Tried every which way, even attempted to put it into the side with the male pins before sticking back together. No dice. Ended up using some Permatex Gray #2 on the inner surfaces of the plastic shell and leaving the grey gasket out.

All of the gaskets are very pliable, no signs of deterioration, but they seem to have swelled, I recall the fit being closer back when I bought the Jeep new.

Have been trying to track down which connection is bad and causing engine to intermittently quit, with the tach dropping to zero until it refires. Already zip-tied the PCM connectors, but not super tight, just snug. It threw an 11 code today, thus the crank position sensor connection check. Also, it has been showing a 72 code, so checking those connections too, but I don't want to end up with a tool box full of gaskets that won't go back into their sockets.

Thanks in advance!
Steve

 

You could try putting some of the dielectric grease on the gaskets to help the connector slide past it. Failing that, I'd personally just fill the connector with the dielectric grease and clean the mess up. The stuff I use is oil and water resistant so will keep both out of the connector and pins just like the original gasket does. If the connector felt a bit loose, I'd cut the gasket down a little so there's just enough to push back to tighten it up.

 

OK, will test out that method.

None of the connectors felt loose, but I am not sure that would be apparent when they are locked together and when released, they aren't connected anymore.

Also, not sure if MOPAR used Weather Pack or something else. None of the gaskets match what Weather Pack offers.

 

By feeling loose I more meant that when locked together, they may be able to wiggle slightly in/out around the locking tab as the original gasket sometimes acts as a bit of a spring.

I haven't really messed with many wiring connectors on my XJ but a lot of newer ones spring tight as the gaskets compresses when locking together.

As for what Mopar used,

 

Tight is absolutely what I have. So tight I could not get one together with the gasket in, and still tight with the gasket out. Guess I should post some pix of what I have tonight/soon.

After doing that O2 connector(?), and still not sure where that one goes, and the crank position sensor harness, I reset the PCM and did not get the 72 or 11 code. Not sure how many cycles it needs for that to be a confirmed fix. It did have a couple of very short hesitations first drive after all that yesterday, didn't have anything amiss this AM.

 

Tight with no gasket sounds very odd. It either sounds like a slightly bent of twisted pin, something still in the connector or a male/female mis-match.

I believe the method for a code reset is to pull the battery leads and leave them off for 15 minutes or so. I could be wrong but it does ring a bell. Time will tell for you anyway.

 

No, not "tight" more like it all clicked together and was a good fit with the Permatex Gray #2, but the plastic housings register and slip together snug dry too. That one O2 plug cannot go together with gasket in.

 

Well, I can't say much more on the gasket issue but it sounds like you should have adequate waterproofing with the grease and Permatex. As the connector is a good fit I'd not worry about it.

 

Seal is in my hand, connector is the cylindrical object.