Sensor plug will not come apart. Need quick help...

Also posted in the technical section but I'm putting it here cause it seems to get more traffic and I need help fast.

So is there a Trick to unplugging the damn sensor from the grill?! Mine will not come off! Im right in the middle of it. Everything else came off without a hitch but the damn sensor plug will not come apart allowing me to remove the grill away from the truck! I don't want to break anything by forcing it. Help!

 

Not sure what the plug looks like on those as I don’t have TSS but after working on tons of vehicles doing electrical work on helpful trick if you’re fully pressing the release tab is to push the connector like you’re plugging it in before pressing the release and then slide back to release it. That helps in a lot of cases.

Also check for a locking mechanism. Some connectors have a locking device you must first slide or remove. Usually they are red, if it has one.

 

Son of a bitch will NOT COME APART!

 

Press the plugs together like you’re connecting them with a bit of pressure. Then press the tab while doing so, and then pull them apart. I should come apart. Sometimes dirt and crap gets in and makes them a little tight. You can spray a little water around the housing or some silicone spray or WD40 to help loosen it up. However it doesn’t really seem to dirty.

 

Push on the tab? Like down toward the wires

 

Finally got it. It was almost as if it was glued together...

 

Looks like you've been prying at it manually with a tool or something.

 

Try pulling the elocker plug on the inside of the diff for 3rd gen, that's a bitch

 

Sometimes you gotta wiggle them a little trying to pull them apart, they can really be tough. Btw don’t use a screw driver to life those releases. You’ll break the locking tab. Just use your thumb on the other end.

 

It was worth the aggravation. Almost there...

 

By the way, I was prying it on all sides between the male and female end with a small flat head hoping to break whatever seal was keeping it from sliding apart. It was a bitch.

Only other one I've ever had this much trouble with was on my Indian Springfield motorcycle.

 

I had the same problem when I changed out my grille bezel. I finally pinched it with a set of pliers to get it separated. What a pain!

 

Praying it like that will make it harder to take off. And big gouges will make it harder to get back on. They can be tough if you have arthritis or carpal tunnel. Some connectors are a royal pain in the ass to get off. Others just have terrible release designs. Like I said earlier, dirt and dust only adds to the frustration. Some of the body harnesses under vehicles can be a loyal pain in the ass due to dirt and small stones and stuff getting wedged into the connectors.

 

I was about to suggest...

but glad i didn't!

 

And the finished product...

 

Did you use plasti dip? Looks great OP!

 

Thank you. No, I used flat black from rattle can...

 

looks very nice

 

Yeah, I get to do this battle again as I change back to my stock TRD/OR grille for the recall. Then, my dealer can inspect the sensor and order parts. All of this just to get the recall closed for my VIN.
Guess my old '81 would really be in trouble...lift kit, oversized tires, wrong grille, push bar
4BYTOY

 

For future reference, I did this the other day and this damn plug held me up. I shoved a small flat head screwdriver underneath the locking tab on the female plug to pry it up while simultaneously applying pressure on the tab lever thingy on the male plug. Came right out.

Way to ditch that nasty chrome! I caved and bought the SR bezel instead.