Need Heater Help

[390FE1972]

When working on my heater box I broke the heater resistor that goes into the metal panel where the heater core comes thru. I found a replacement at the junk yard. I am having problems getting the heater resistor to go back into the wiring harness. There are three prongs on the heater resistor that plug into the heater wiring harness. I cleaned the connections on the harness with electrical connector cleaner and I put dielectric grease on
the three prongs of the heater resistor after cleaning the prongs up. I can get the prongs started into the harness but I am about a half inch from
getting the plug on all the way. Does anyone have any suggestions for getting the plug on all the way without breaking the resistor? Is there another
source for these heater resistors other than the junk yard? I couldn't find them for a 1972 F250 on any of the web sites or catalogs. These heater resistors are very fragile and break easily.

Thanks!!!

[sargentrs]

Ford was prone to not reinvent the wheel sometimes. Went through something similar when rebuilding my factory under dash AC unit. Couldn't find a resistor anywhere. Took a chance and ordered one for '69-'70 Torino with factory AC. Turned out to be a perfect match, hole centers were even the same. Surf the Mustang/Torino restoration sites and order one for a similar generation with heater only that looks like it. Probably exactly the same. Worse case you might have make an adapter mounting plate out of a piece of stiff. Check out what I did with my AC unit. http://www.fordification.com/forum/view ... 3&start=45 (toward the bottom of the page).

[390FE1972]

Thanks for the reply sargentrs, any ideas of why this connection is so tight? When I took the resistor off I had to use a screw driver to pry it off. Wish I had left it on the harness when I went to rebuild my heater box. I had the same problem with the one I took off at the junk yard. I wonder what Ford used at the assembly plant to prevent braking the resistor when they installed them. Not the greatest design in my opinion.

[Ranchero50]

I wonder if the application didn't 'dry' out the plastic plug and cause it to shrink some. I don't remember mine being terribly difficult to remove. Maybe soak the parts in some baby oil for a couple days. I've done that in the past to rejuvenate dry dashe pads and it works wonders.

Might not make it go together easier but it will make your hand soft.