GS450H Motor Connectors

[dso]

I have a GS450H motor but some of the harnesses are missing. Does anyone know what connectors these are, and if they are available?

https://imgur.com/a/AyJn4Eg

[sfk]

Looks like that gearbox has been sitting outside in the weather for awhile!

Not sure about the connector types. The 3rd one is probably for reporting back the currently selected gear.

I have seen wiring harnesses for this gearbox for sale on Yahoo Auctions Japan for reasonable price.

[xp677]

They will likely be TE/AMP/TYCO or Sumitomo connectors. The second one looks like a Sumitomo.

Chances are some of them will be unique to Toyota, so not available from normal sources. If you can't get hold of a harness, I'd suggest using loose pins that will mate with those connectors, and then filling the connector housing with epoxy to set the pins. You can then add your own connectors as required.

[dso]

Thanks for the suggestions. It looks like the connectors might be the following:
Sumitomo 6189-0175
Sumitomo 6189-1092

Not found the last one yet.

[xp677]

Bear in mind that the first connector is for the output shaft speed sensor, this is a variable reluctance sensor, you will need a MAX 9924 or similar to interface with this, and it's rather pointless since the inverter sends MG2 rpm within its MTH packet.

[Dre.esky]

Hence we don’t need to worry about the first two sensors but how about the third connector transmission selector switch

[arturk]

The "SHIFT LEVER POSITION SENSOR" connector is tough one. OEM may be the only option besides some "custom" job.
I am going to look into getting plug assembly or housing from Toyota/Lexus dealer but it may be very expensive and they usually have housings only without pins.
I will report my findings.

Anyways, as functionality goes, my understanding is that lever locks output shaft mechanically to to provide PARK brake and sensor provided feedback to control module which gear is selected by sending +12V to appropriate pin.

Therefore it will be very important to have it wired to VCU to prevent and perhaps limit torque at certain positions.

UPDATE:
No luck at local dealership. They use some external system (not Toyota) to lookup and order electrical connectors. Most of those plugs are not available from Toyota individually but only as outrageously expensive complete harnesses.
I had some luck ordering various connectors such as for headlights and other more basic.

I did find at leas one "Engine Harness" with "shift lever position sensor connector" but at $250 price tag am going to pass.
At least I got picture (attached).

If this cannot be found anywhere perhaps we will 3D Print it. I have done it before successfully for simple plugs. For these I think it would be possible but actual 3D design would be the hardest part as I am not very skilled in this area.

UPDATE 2:
I have discovered part number of this connector which is "90980-12362".
In US it is being sold by vendor named Godaca LLC and here is few links:
http://godaca.com/1x-connector-7-way-fo ... 980-12362/
https://www.amazon.com/Connector-7-way- ... B07RHVGHBH
https://www.ebay.com/itm/1x-Connector-7 ... 4313452300

Honestly, I did not think it was possible to purchase it but here it is! I have already ordered mine

[Dre.esky]

Nice good work gonna order too

[arturk]

Here is part number for A62 Inverter Connector: 90980–12630

[xp677]

Anyways, as functionality goes, my understanding is that lever locks output shaft mechanically to to provide PARK brake and sensor provided feedback to control module which gear is selected by sending +12V to appropriate pin.

Yes, park is a parking pawl, the other selections are all the same mechanically. It follows this wiring:



For my application I connected the white +B wire to ground, and commoned the R,N,D wires, to give two positions for this switch. If you want to reuse an existing mechanical shift lever, using the 4 or 5 available positions of the switch would be a good way to do it.

[dso]

Does anyone have the pinout for the Sumitomo 6189-1092 on the motor?

[arturk]

Here is what I have.
Please pay attention at Harness (Left) and Components (Right) sides.

[dso]

Awesome thank you.

[streber]

Does anyone know the part numbers for the harnesses that plug into the transmission and inverter?

I've figured out:
8216430040 is the harness from the battery to the inverter and is the two smaller white connectors.
8211130* appears to be the main engine harness and I think contains the connectors from the EV ECU and the Inverter (big plug), but can't confirm that or exactly which variant if it matters.
8212130D10 appears to be the ICE harness and does not appear to be the right one.

No clue for the rest of the transmission, although those seem much easier to replicate than the shielded stuff in the EV ECU <-> Inverter connection.

[RE3Rotor]

My 450h motor is missing the resolver plugs. Does this look correct to you folks? As for the four twisted pair, can I just wire them up using some CAT6 cables?

https://www.aliexpress.com/item/4000132 ... hweb201603_

[arturk]

My 450h motor is missing the resolver plugs. Does this look correct to you folks? As for the four twisted pair, can I just wire them up using some CAT6 cables?

https://www.aliexpress.com/item/4000132 ... hweb201603_

Yes, this is correct plug.
Keep in mind those wires have to be shielded, CAT6 shielded should work just fine. I would try to find thick 24AWG or 26AWG minimum.
I am using CAT8 S/FTP 24AWG with each pair is individually shielded.

[RE3Rotor]

Yes, this is correct plug.
Keep in mind those wires have to be shielded, CAT6 shielded should work just fine. I would try to find thick 24AWG or 26AWG minimum.
I am using CAT8 S/FTP 24AWG with each pair is individually shielded.

Awesome. I watched your video and those cables look great. I said CAT6 because I can easily get the scraps from work being in IT.

[xp677]

The 4 signals use CAN transceivers, so you should follow the requirements for CAN. Cat6 should be fine as each pair is individually screened, but who knows.

[RE3Rotor]

Does anyone have pinout for the resolver connections? Or all the different connections on the gearbox? Or if they can provide me screenshots of the section of the service manual, I can compile that together. I don't have all the wiring harness to go between the inverter and gearbox. I think it is valuable for those of us who needs to build a harness from scratch.

[Dilbert]

Here is an image of the connector, looking at the front of it.

[RE3Rotor]

Thank you.

[Dilbert]

The remaining two pins 4 & 8 are the motor temperature sensor, these don't connect to the inverter, they connect to the Vehicle ECU.

[RE3Rotor]

I thought I had it figured out but I don't. Do you happen to know what the two prefixes (M & G) on the resolver wiring denotes MG1 & MG2 respectively?

[Dilbert]

The wiring diagram is here https://openinverter.org/wiki/images/a/ab/Inverter.png

The pin numbers and signal named in the above diagram align with the earlier connector pin out I posted.

The ones starting with G are MG1 and M are MG2.

[RE3Rotor]

Luckily I have the harness from the gearbox to this oil pump controller. But do we have the diagram for the controller?