Checking Terminal Contact

Many tables direct you to check terminal contact before replacing a component. This is done because the checks performed in 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 terminal contact prevents the replacement of good components, prevents returns due to intermittent connection problems, and makes some repair jobs easier, as in replacing a terminal instead of a component. For this reason it is very important to check terminal contact when instructed to do so.

Checking terminal contact is easy if you have a supply of new terminals handy. The Connector Test Adapter kit is a good source of terminals for checking terminal contact. The kit contains a supply of all currently used terminal series and also has the male terminals (12047581) and female terminals (12052922) necessary to build the diagnostic jumper for ignition control DTC diagnosis.

To check terminal contact, start by inspecting the male terminals. The terminals should be straight and aligned with other terminals in the row. The terminals should not be twisted, bent, or otherwise damaged. The female terminal should 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 to be checked. The terminal should not fall out or be easily jarred out of the connection. Some force should be required to disconnect the terminal. The force required to disconnect the terminal depends on the size of the terminal being checked. Larger terminals, the Metripack 630 series for example, should be very difficult to remove by hand. 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. Refer to Connector Repairs in Diagrams and the terminal repair kit for identification of terminal series and for the repair procedures.