Repairing Connector Terminals (Terminal Repair): Notes
Special Tools
- J-38125-580 Terminal Repair Kit
- J-38125-6 Crimp Tool
- J-38125-7 Crimp Tool
- J-38125-8 Crimp Tool
- J-38125-64 Crimp Tool
- J-38125-101 Crimp Tool
- J-38125-641 Crimp Tool
- J-38125-642 Crimp Tool
- J-38125-643 Crimp Tool
For equivalent regional tools, refer to Special Tools .
Use the following repair procedures to repair each type of terminal:
- For push to seat terminals, refer to Delphi Connectors (Weather Pack) , Delphi Connectors (Pull To Seat) , Delphi Connectors (Push To Seat) , Delphi Connectors (12-Way) , Delphi Connectors (Micro.4) , Delphi Connectors (Steering Gear) , Delphi Connectors (Micro-Pack 100W) .
- For pull to seat terminals, refer to Delphi Connectors (Weather Pack) , Delphi Connectors (Pull To Seat) , Delphi Connectors (Push To Seat) , Delphi Connectors (12-Way) , Delphi Connectors (Micro.4) , Delphi Connectors (Steering Gear) , Delphi Connectors (Micro-Pack 100W) .
NOTE:
The first step for all terminal repairs is to find the connector end view in SI.
Cable Seal Terminals
- Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
- Remove the old seal.
- Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation.
- To minimize wire loss, remove only the insulation required.
- Using the connector end view, determine the correct crimp tool and crimp jaw.
- Align the seal with the end of the cable insulation.
- Position the stripped wire and seal in the terminal.
- Hand Crimp the core wings first.
- Hand Crimp the insulation wings around the seal and the cable.
- Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes.
Unsealed Terminals
- Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
- To minimize wire loss, remove only the insulation required.
- Position the stripped wire in the terminal.
- Hand Crimp the core wings first.
- Hand Crimp the insulation wings around the cable.
- Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes.