Stubborn fan switch connector for on radiator

[stanrob]

Apparently nobody else is having (or reporting) this problem:
At 305,750 miles, the radiator is crying out for replacement.
Overheating is an issue fully loaded climbing hills at 95 degrees F.
I'm trying to replace it but can't get the fan switch connector off.
I know, it should slide right off when its release lever is pressed.
It did so on our previous Tercel at ~194,000 miles.
It apparently did so in all the other pertinent tercel4wd postings to date.
Well, this one doesn't.
My brute strength is unimpressive, but I've tried it.
I've also tried to pry it by rotating a large flat-blade screwdriver on a position around from the release lever.
That gets about 1mm at most, then it reverts to the original stuck position.
I'd prefer not to break anything.
Ideas? Similar experiences?

[rer233]

Never had that problem. If all else fails, you can always cut the wire(s) and unscrew the switch/plug assembly from the old radiator. Then install the new rad, screw in the switch, (and this part's important) SOLDER the wires back together. Shrink wrap would also be a good idea.

Good luck, hope this helps.

[Petros]

I spray it with penetrating oil, let soak a bit, and try it again. also those long nose break pliers give you a good grip. sometimes either the o-ring sticks, or the contacts get corroded, and they make it difficult to remove.

[stanrob]

Hey Petros, you've rescued me once again! THANK YOU.
One small squirt of PB Blaster, a few taps with a screwdriver handle.
Still holding fast, but wait.
Came back in ~45 minutes, and got it off with my aging bare hands.

[Petros]

good to hear it. no cutting or splicing and no extreme measures, just let it soak a bit.

I have had this kind of thing happen lots of times, on other cars as well. the plastic connector housing will not take a lot of abuse, I have actually damaged them trying to force them apart with tools. Only adds to the frustration of an otherwise simple and straight forward job. I have come to despise the electrical connectors on Hondas, they get stuck often and are always in very had to reach places. The penetrating oil usually does the trick.

[stanrob]

New radiator arrived and is now in!
Various surprises encountered.
One big one: fan shroud blocked removal of the old one. I had to remove grill and demount the fan shroud.
One small one: had to transplant the thermostatic switch; then I noticed that its O-ring had stretched out.
Might explain why it was so hard to remove the connector.
I had another with a good O-ring, used that instead.
Thanks to all.

[rer233]

Yeah, I've had the same clearance problem with the cooling fan.

[Petros]

the lower lip of the fan shroud overlaps the lower edge of the radiator lower tank. I use a really big screw driver or a large flat bar I feed down in front of the radiator to get behind it and pry it back. it is always a real nuisance, I have also had small stones get caught in this shroud against the radiator and eventually wear a hole in it, causing a leak. I always bend the mounts to move the fan assembly forward when I have a chance, so next time it will not be such a PIA, and preclude damaging the radiator since I drive on rough gravel roads daily. I think toyota may have made a mistake on this fan mount, it should have been about 1/2" (12mm) further forward to prevent this trouble.