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Terminal Replacement Procedure
HOW TO R E P L A C E CONNECTOR TERMINALS
The terminal repair kits provide necessary tools and
materials (terminals, wire seals, and splice connectors)
to repair many damaged or faulty connector terminals.
However, not all terminals for all connectors are
available. Refer to the labels on the lids of the repair
kits for replacement terminal availability.
IMPORTANT S A F E T Y INFORMATION:
On some models, the SRS wires are in a separate
harness. If the SRS harness is damaged, replace
the harness; do not repair it. On other models,
wire harnesses include fellow SRS wires. If any
SRS wire is damaged, replace the entire harness;
do not repair it.
Before you begin, inspect the wire you are about to
repair for damage and length. Make sure the wire will
be long enough to make a terminal repair without
stretching it when you reinstall the terminal in the
connector. If the wire is too short, or if access to the
connector is too restricted to make a terminal repair,
you may need to install a pigtail terminal (a short
length of wire with a factory-crimped terminal on it).
Refer to HOW TO INSTALL PIGTAIL TERMINALS.
Removing the Terminal
Use the tools from Pin Tool Set.
First, check the connector that you are about to repair.
• If it has a secondary terminal lock, go to Connectors
With a Secondary Lock. A secondary lock, found on
most connectors on some models, is an additional
locking device on the connector housing as a
backup for the primary lock on the terminal.
• If the connector does not have a secondary lock, go
to Connectors Without a Secondary Lock.
Connectors
With a Secondary Lock
All examples are shown with the connector lock facing
up. The illustrations are examples of the secondary
terminal locks; however, the connector you are
repairing may vary in size. Identify the connector by
the type of secondary lock, not by the number of
terminal cavities.
EXAMPLE A:
1. Release the secondary lock.
Lift u p o n t h e s c r e w d r i v e r a n d
t h e lock will " s n a p " u p w a r d .
2.
Remove the terminal.
Insert t h e tool in this
P u s h t h e w i r e into t h e
cavity a b o v e t h e
c o n n e c t o r t o relieve t e n s i o n
t e r m i n a l until it s e a t s .
Pull t h e t e r m i n a l out
of t h e connector.
3. Go to HOW TO INSTALL NEW TERMINALS.
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