Checking Terminal Contact

Many diagnostic tables will have you checking the terminal contact before replacing a component. This is done because the checks that are performed in the diagnostic tables can only check the continuity of a circuit across a wire or in-line connection, not the continuity across the connection at a component. Checking the terminal contact will prevent the replacement of good components, prevent comebacks due to intermittent connection problems, and make some repair jobs easier (e.g. replacing a terminal instead of a component). For this reason, it is very important to check the terminal contact when you are instructed to do so.
Checking the terminal contact is easy as long as you have a supply of new terminals handy. The Terminal Repair Kit. J 38125, is a good source of terminals for checking the terminal contact. The kit contains a supply of all currently used terminals. In order to check the terminal contact. start by inspecting the male terminals. The male terminals should be straight and aligned with the other terminals in the row. These terminals should not be twisted. bent or otherwise damaged. The female terminal should be also be inspected for alignment and damage. Finally, take a new male terminal of the same series (e.g. Metripack 150, Weatherpack, etc,) and connect the male terminal to the female terminal(s) that are to be checked. The terminal should not fall out or be easily jarred out of connection. The terminal should require some force for a disconnection.
The force that is required to disconnect the terminals will depend on the size of the terminal being checked. The larger terminals. The Metripack 630 series for example, Should be very difficult to remove by hand. The smaller terminals, the Micropack series for example, should be easier to disconnect by hand but still should not fall out. Replace, do not repair. any damaged terminals.