Stereo head unit interface issues :(

[GRNSHRK]

OK gents, I'm having a real bitch of a time getting my old Sony pullout stereo head unit to make a good solid connection with the mating connector

I can get all channels to work, but it requires moving the individual connectors around, specifically one channel, as 3 out of 4 work reliably

I've tried contact cleaner, springing out the contact points farther to make a better connection, even filing the contact surfaces, which probably isn't the best idea either

At this point I'm open for suggestions, as this is starting to drive me crazy and I would like to wrap this project up

As usual, TIA

[hornhospital]

My suspicion is the poor contact is within the removable plate rather than the plate/head unit interface itself. Those have a certain amount of flex within the plate, and the flex is responsible for the failing/failed connections.

[GRNSHRK]

Ken, are you referring to the type of head unit that had a removeable front panel

This is not that type, the entire head unit slides in and out, making contact when inserted, hopefully

I'm going to work on checking the alignment, a suggestion from Craig in Paso, after discussing this issue with him earlier today

Hope you're feeling better Ken, and check your email when you get a chance

[hornhospital]

Yes, I was thinking of the removable faceplate type unit. I misunderstood.

Gradually getting better. Appetite is back! LOL!

[633_Dream]

I would not be surprised if the connectors solder joints inside radio are cracked.

Typically the plug should be fine. There is no corrosion visible.

You might also check if any of the pins is not bent or made flat after some time of usage. It happens.

[GRNSHRK]

I've been inside the unit as well, a few times, checking things, but the leads go to connectors, no solder joints to crack

I'm still thinking that the interface has issues, possibly alignment, as suggested by a fellow board member

But there are 2 alignment pins so you really can't misalign it, once you slide the head unit it

I was just working on it again today, to no avail

I am really temped at this point to hard wire everything