Repairing Connector Terminals

Repairing Connector Terminals

Special Tools
* EL-38215-10 - Splice Sleeve Crimp Tool
* EL-35616-D - Terminal Test Probe Kit
* J 38125-5 - Ultra Torch
* Terminal Release Tool Kit

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Making a Repair with a Terminated Lead or Connector Assembly

1. If using a terminated lead, remove the terminal to be replaced with the appropriate terminal release tool. Refer to the Terminal Release Tool Kit.
2. Cut and strip the wire insulation away from the terminal leaving enough wire length to reassemble the harness and connector without causing binding or a pinch condition.
3. Crimp the splice sleeve to the terminated lead or connector assembly to the harness wire using the EL-38215-10 - tool. Refer to Splicing Copper Wire Using Splice Sleeves (Splicing Copper Wire Using Splice Sleeves).
4. Use the J 38125-5 - torch to seal the splice.
5. Repeat steps 2-4 if a connector assembly is being used to repair the vehicle.
6. Reassemble the connector and harness.
7. Verify the repair.