Ground Block Installation and Pinout for 9100
Connector & Splice Instructions for The Switch-Pros Ground Block
Tools & materials
F-type ratcheting crimper with appropriate die and wire stop.
- Crimp tool/die for multi-wire splice barrels; adhesive-lined heat shrink.
- Adjustable wire stripper (with stop), heat gun, ruler/gauge, thin zip ties.
- 26 pos Superseal style housing and matching female terminals.
- 16 AWG TXL for connector pigtails (all pins). 10 AWG TXL for C1–C4 mains. 12 AWG TXL for long C5–C8 mains.
- Multi-wire splice barrels sized for combined conductors; cable ties and loom for protection.
Key rules (read before starting)
- Crimp terminals onto 16 AWG pigtails first.
- Keep every pigtail trimmed to an identical finished length measured from the terminal shoulder before splicing.
- Do not insert terminals into the housing until after splices are completed.
- Keep terminal faces aligned while building splices; use thin zip ties at each end of the bundle to prevent rotation.
Bench checklist
- F-type ratcheting crimper with wire stop ready
- Splice crimper and correct die ready
- 26 pos housing & female terminals on bench (all cavities filled)
- 16 AWG pigtails cut long, and terminals crimped (not inserted)
- All 16 AWG pigtails trimmed to identical finished length from terminal shoulder (before splicing) - Thin zip ties applied to each end of pigtail bundles to maintain orientation
- Mains prepped with heat shrink (10 AWG for C1–C4; 12 AWG for C56–C8)
- Splice end strip lengths set (16 AWG = 8.0 mm into splice; 12/10 AWG = 8.0 mm into splice)
- All splices completed and heat shrunk (S1–S8)
- All terminals are inserted straight into the housing, and face/TPA pushed in to lock terminals
- Wires routed, splices protected, continuity and short checks done
1 — Crimp pigtails and trim to an identical length
- Cut all 16 AWG pigtails long enough to strip, crimp, and reach the splice point (leave extra for routing).
- Set the stripper stop to 4.5 mm and strip each 16 AWG pigtail. Crimp the female terminal with the ratcheting crimper; inspect each crimp.
- Trim every 16 AWG pigtail to the same finished length from the terminal shoulder before making any splices.
2 — Prepare mains and preposition the heat shrink
- Slide adhesive-lined heat shrink onto each main conductor before stripping.
- Strip mains to 8.0 mm for splice insertion (12 AWG and 10 AWG splice ends use 8.0 mm). For 12 AWG terminal crimps, use 6.5 mm where applicable.
3 — Align terminals for splice assembly (rotation and zip tie tip)
- Lay out crimped 16 AWG pigtails so the locking lance faces the same direction.
- Place a thin zip tie snugly (not crushing insulation) at each end of the pigtail bundle to keep terminals from rotating and to maintain alignment while you assemble splices.
- Keep the bundle orientation consistent for every splice group so terminals will face correctly when inserted later.
4 — Splice procedure (do this before inserting terminals)
- For C1–C4 (35 A): group four 16 AWG pigtails into the splice barrel with the 10 AWG main; insert conductors fully and crimp with the correct die; heat shrink.
- For C5–C8 (20 A): splice two 16 AWG pigtails to a 12 AWG main (single 16 → single 12) using a properly sized barrel and die; crimp and heat shrink.
- Inspect every splice for full compression and adhesive flow; secure splices with cable ties and route away from sharp edges.
5 — Insert terminals into the connector and lock
- Hold the housing so the terminal retention springs face up. Orient each terminal with the locking lance up.
- Push each terminal straight into its cavity until it bottoms out; do not rock or angle. Insert all terminals before operating the face/TPA.
- After seating every terminal, push the connector face/TPA inward until it snaps to engage the secondary lock.
6 — Final routing, protection, and checks
- Secure pigtails and mains with cable ties and loom; keep splices accessible but protected.
- Confirm no bare conductor is visible and that hole plugs (if used) are seated.
- Perform continuity and short checks from each connector pin to its main conductor. Under expected load, briefly monitor splice and connector temperatures for abnormal heating.
Practical tips and quality checks
- Use adhesive-lined heat shrink and fully seat it over the splice; off-road environments need moisture and vibration protection.
- If a terminal resists insertion after splicing, check orientation and that the locking lance is undamaged.
You can download a PDF of this blog by clicking here
- What wire gauge do I use for the 9100 ground block mains?
- C1–C4 (35A circuits) use 10 AWG TXL mains. C5–C8 (20A circuits) use 12 AWG TXL mains. All channels use 16 AWG TXL pigtails at the connector.
- What type of heat shrink should I use on the splices?
- Adhesive-lined heat shrink only. Standard heat shrink provides mechanical protection but no moisture seal. The adhesive melts and flows around the wire when heated, creating a true waterproof barrier required for off-road use.
- How do I lock the terminals in the connector housing?
- Insert all terminals straight into their cavities until they bottom out — do not rock or angle them. After all terminals are seated, push the connector face/TPA inward until it snaps to engage the secondary lock.
- Is there a downloadable pinout diagram?
- Yes — a PDF pinout is available at the bottom of this guide.