Terminal Removal
If the terminal is visibly damaged or is suspected of having a faulty connection,
the terminal should be replaced.
Follow the steps below in order to repair pull-to-seat connectors:
- Remove the connector position assurance (CPA) device and/or the secondary
lock.
- Disconnect the connector from the component or separate the connectors
for in-line connectors.
- Remove the terminal position assurance (TPA) device.
- Insert the correct pick or removal tool into the front of the connector
body.
Important: On connectors with more than one terminal
the service loop may not be large enough to remove the terminal and crimp on a new
one. If the terminal wire does not have a large enough service loop for removal,
cut the wire 5 cm (2 in) behind the connector before removal.
- Grasp the wire at the back of the connector body and gently push the terminal
(1) out the front of the connector body (3).
Terminal Repair
- If the wire needed to be cut in order to remove the terminal, gently push
a small length of the same size wire through the back of the connector cavity until
there is enough wire exposed in order to crimp on a new terminal. If the wire was
not cut, cut the existing wire as close to the old terminal as possible.
- Strip 5 mm (3/16 in) of insulation from the wire.
- Crimp a new terminal to the wire.
- Solder the crimp with rosin core solder.
Terminal Installation
- Align the terminal and pull the wire from the back of the connector in
order to seat the terminal.
- If necessary, cut the new wire to correct length and splice with existing
circuit. Refer to
Splicing Copper Wire Using Splice Sleeves in Wiring Systems.
- If the connector is outside of the passenger compartment, apply dielectric
grease to the connector.
- Install the TPA, CPA and/or the secondary locks.