Help- DDRP install gone awry

[Reluctant Mechanic]

Last fall my FASS DDRP started fluctuating pressure wildly. Thought it was dying and bought just the replacement pump from FASS. Forgot how hard it was to install! After done the new pump had the same problem! Long story short, it turned out the batteries failed the cranking amp test so got new ones and the pressure popped up to normal. All was well except…once in awhile the pressure would drop to zero on start up, sit there for a bit, finally pop up and be fine. But this was disconcerting to say the least.

I screwed up the new install by cutting the fuel line such that the inline filter FASS wants you to add was up against my starter and too hard to get to. I decided to buy some marine fuel line and replace the span from the fuel pump inlet to the inline filter so it could be reached from under the truck and not be rubbing on anything.

Optimistic, today was the day. When it came to trying to re-install the inlet side, we couldn’t get the bracket in place and the banjo bolt lined up with the hole. The decision was made to remove the pump. When I went to unplug the pump for some reason I did the wrong one and tried to do the one that attaches to the engine. While trying to do so, the wires pulled out of the harness plug!
It’s so tight down there and there’s no slack to work with! Trying to feed those wire ends back into the plug end was impossible.
What are my options?

Last of all, it seems the wires into this plug end were loose and why they popped out so easily, so the possible cause of the pressure fluctuations?

If I need to get a replacement plug - don’t know what to call this thing, is it something I can get at an auto parts store or do I have to order some bleeping expensive Mopar part?

Suggestions welcome!

 

[SAndreasen]

Crimp new ends on it cut the plug off the pump and crimp opposite ends on the wires heat shrink the connections and be done

 

[Reluctant Mechanic]

So to be clear, the black plug with the orange is the end that plugs into the FASS and the grey end is the female to the engine side plug that came apart, so cut out the grey harness entirely and splice the two ends together? I wondered why there were two harnesses to begin with, seems a single cable coming straight to the pump harness would be enough.

Thank you!

 

[Ozymandias]

So to be clear, the black plug with the orange is the end that plugs into the FASS and the grey end is the female to the engine side plug that came apart, so cut out the grey harness entirely and splice the two ends together? I wondered why there were two harnesses to begin with, seems a single cable coming straight to the pump harness would be enough.

Thank you!

One is the factory plug, the other adapt the FASS.

 

[petersonj]

If I need to get a replacement plug - don’t know what to call this thing, is it something I can get at an auto parts store or do I have to order some bleeping expensive Mopar part?

I believe the connector you are referring to is a Deutsch 2-pin connector. You can buy a pair from Amazon for about $10.00 and splice it in.

- John

 

[BigPapa]

You can get the same one as PJ linked above, but if you need to do it now, any 2-pin connector will work, you just need both sides. O’Reilly’s or any other parts house should have them.

 

[Topzide]

From the looks of the connector that you show, you could remove the pins and re-crimp the wires. A good pair of crimpers that have different dies to put in them for different terminals.
If you go another route, you can use hot melt glue under the heat shrink to weather proof the connection. Have done this for a LED if an outdoor fountain feature. Been in use several years now without fail! Good luck with repair.

 

[Ozymandias]

I prefer Shrink tube that is already glue lined from the factory.

 

[JeepBuilder]

I only use the epoxy lined terminals and heat shrink now. And investing in the right crimpers is helpful. When you are done use a heat gun and shrink till the epoxy shows in the end of the shrunken sleeve. Me being a jeeper and taking rigs (not my dodge) in places where water and mud happen, these terminals have the best protection. Shy of a weatherpak or other sealed connector that is. That looks like a fun repair... sort of.