I posted this at another site. I though I would repost it here as well... just in case
The strut plug repair kits are no longer available from the dealer. So the only option is to repair or replace with a good used donar part. And as far as I can tell This part is only manufactured for the allante. I checked my sls and it is a bigger plug.
Replacing with a donar part is pretty staight forward, but you can repair them if no donar parts in your area.
As time goes on there might not be any donar parts left, and we will be forced to repair
Here is what I did. ( I also bought 2 used plugs for the future ).

The 1st pic is of the broken wire on the plug, all 3 were broken when I actually got it off.

http://i189.photobucket.com/albums/z43/cap4000/01.jpg

Turned the unit upside down and used a small jewelscrewdriver to pry of little yellow cap, pry several spots around alittle at a time ( so you don't break it).

http://i189.photobucket.com/albums/z43/cap4000/02.jpg


Forward push the pins with the same screwdriver. Thereis a locking mechanism so use 2 drivers, figit a little and they will come out.

http://i189.photobucket.com/albums/z43/cap4000/03.jpg

This is the result

http://i189.photobucket.com/albums/z43/cap4000/04.jpg

You can then bend apart the wire clips holding the wireand solder in new wires. Then just reinsert. I used just the smallest amount of super glue in 2 spots for theyellow end cap ( don't want it staying in the shock the next time you pull it off )

http://i189.photobucket.com/albums/z43/cap4000/05.jpg

Then out to the car soldering the new wires to the oldones using heat shrinking tubes for each wire and alarge one for all to make it water proof.

http://i189.photobucket.com/albums/z43/cap4000/06.jpg

http://i189.photobucket.com/albums/z43/cap4000/07.jpg

http://i189.photobucket.com/albums/z43/cap4000/08.jpg

and now a happy car, no sdd warning ( thought I mighthave to clear some codes or something, but after initialstart warning cleared and a drive it never came back on)

http://i189.photobucket.com/albums/z43/cap4000/09.jpg

note: make sure you note the original wire placement soyou can match up to the original wires.
Also soldering to the car might not be needed for all cars. The 2 donar plugs I bought for future needs that I got fromtoms allantestore have a connector on them, They were labled 1990 on them. You could then just replace the wire between both ends by pushing out the pins.....
I hope this will help someone in the future....



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Moderator edit
Title

this is a great thread.
thanks for the technical and the photos.

Cap

That's what I'm talkin about!!!!!!!!!!