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OEM crimped connectors for relay and fuse box

Discussion in 'Electrical' started by rSw, Oct 25, 2024.

  1. Oct 25, 2024 at 9:56 AM
    #1
    rSw

    rSw [OP] New Member

    Joined:
    Mar 25, 2024
    Member:
    #114261
    Messages:
    2
    Gender:
    Male
    Vehicle:
    2024 Tundra TRD
    I looked for an existing thread on this, but didn't find one. I apologize if I missed one. I do see a similar thread on the Tacoma forum.

    I would like to install the ARB dual-pump air compressor and a reservoir in my new (under warranty) 2024 Tundra. Looking at the RH engine compartment fuse and relay box, there appears to be a lot of space for additional relays in the box (since I went cheap on options!). I believe there is enough physical space for the compressor directly above this relay box if I fabricate a hinged mount for the compressor. The compressor requires two 40A relays and fuses. I would like to hear from the forum on the following questions (and any other advice offered):

    1: If I can source (more on this below) the loose, OEM crimp terminals and then wire the compressor directly to the fuse and relay box, using a suitable OEM relay, will it likely void my warranty?

    2: Aside from voiding the warranty, is there a reason not to wire the compressor to the OEM fuse and relay box? Assume I will use proper crimpers, wire gauge, and good shop practices, and I have sufficient experience.

    3: If the minimum quantity of crimp terminals is large, would anyone be interested in going in on an order?

    I started down this rabbit hole, looking at the seemingly-sufficient available space above the RH fuse and relay box, and thought, "That would be a nice, short wire run!" Then, looking in there, I found two spots that would accommodate an OEM 50A relay, and 50A fuses (I will use 40A components, which have the same form factor). One is populated with terminals, and is labeled AIRSUS (for the auto leveling suspension option I don't have). The other is a hole, into which snaps a plastic relay block (I'm trying to identify this part number, but I expect I'll be able to do it). Rather than dissect my new truck, I harvested a fuse and relay box from a 2007 Toyota Sienna at the pick-n-pull for $25 (it came with a nice inventory of used relays as a bonus).

    The terminals in the relay blocks and fuse sockets in the donor fuse box are apparently identical to those in my 2024 Tundra. I de-pinned a 40A relay block and a fuse socket to get the terminals on the bench, I photographed and measured the terminals, and then I had a long email exchange with a company that builds and repairs harnesses (they were very patient with me). They identified the three special terminals, and can sell them to me in a minimum quantity of 20 pieces each, to the tune of ~$400.

    If I can't afford to source the loose terminals, I do have some nice 10ga pigtails from the donor box that I could use with crimped "environmental" butt splices (the kind where the sleeve and the heat shrink are separate, and create a water-tight connection). So I could cobble the wiring together that way, but Questions 1 and 2 above remain...

    The mystery on identifying these terminals seems to be due to the fact that Toyota and other auto manufacturers list a part number for the entire harness, not the terminals. The person at the parts counter at the dealership definitely can't help. I believe connector shells are easier, but the identities of the terminals themselves (especially in the fuse and relay box) are apparently proprietary information. I spent hours on various sites trying to match them visually with similar terminals offered, but just wound up frustrated and behind on work I should be doing. I know there are many nice options for adding additional busses via the battery post, etc. but I thought if I could pull this off it would be extra nice.

    Thanks for any and all advice!
     

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