Repair Instructions
CONNECTOR REPAIRSPush-to-Seat Connector
Connector Repairs: Push-to-Seat Connector:
Follow the steps below in order to repair push-to-seat connectors.
1. Remove the Terminal Position Assurance (TPA) device, the Connector Position Assurance (CPA) device, and/or the secondary lock.
2. Separate the connector halves.
Connector Repairs: Push-to-Seat Connector:
3. Use the proper pick or removal tool (1) in order to release the terminal.
4. Gently pull the cable and the terminal (2) out of the back of the connector.
Connector Repairs: Push-to-Seat Connector:
5. Reform the locking device if the you are going to reuse the connector.
6. Make the repair.
^ Slip the cable seal away from the terminal.
^ Cut the wire as close to the terminal as possible.
^ Slip a new cable seal onto the wire.
^ 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.
^ Slide the cable seal toward the terminal.
^ Crimp the cable seal and the insulation.
^ If the connector is outside of the passenger compartment, apply grease to the connector.
^ In order to reuse a terminal or lead assembly, see the splicing copper wire.
^ Ensure that the cable seal is kept on the terminal side of the splice.
^ Insert the lead from the back until it catches.
^ Install the TPA, CPA and/or the secondary locks.
Pull-to-Seat Connector
Connector Repairs: Pull-to-Seat Connector:
Follow the steps below in order to repair pull-to-seat type connectors.
1. Separate the connector halves.
2. Use the proper pick or removal tool in order to remove the terminal.
^ Gently pull the lead.
^ Insert the pick from the front of the connector into the canal.
^ Pry up on the tab.
^ Push on the lead in order to remove the lead.
3. If the terminal is to be reused, re-form the locking tang.
4. Make the repair.
^ Pull the terminal wire out of the connector body.
^ Cut the wire as close to the terminal as possible.
^ Strip 5 mm (3/26 in) of insulation from the wire.
^ Crimp the new terminal to the wire.
^ Solder the crimp with rosin core solder.
^ Carefully pull on the wire in order to draw the terminal into the connector body until it locks.