Sumitomo Connectors

Sumitomo Connectors

Special Tools

* EL-38125-580 - Terminal Release Tool Kit

* J-38125-12A - Terminal Release Tool

* J-38125-552 - Terminal Release Tool

* J-38125-553 - Terminal Release Tool

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

Terminal Removal Procedure




1. Slide the lever lock forward while pressing down on the lever lock release tab.






2. Disconnect the connector from the component.




3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover.




4. Relieve the tension on the nose piece retainers by inserting J-38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece.




5. Once the nose piece retainers are relaxed, use the J-38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly.




6. On the opposite side of the nose piece, use the J-38125-552 pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side.




7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity.

* Terminal (1)

* Entry Canal (2)




8. Insert the J-38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector.




9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer.

10. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminated Lead Repair)Repairing Connector Terminals (Terminal Repair) Repairing Connector Terminals (Terminal Repair) procedure.

11. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.

Terminal Insertion Procedure

After the terminal is replaced, perform the following procedure in order to insert the terminal.

1. Slide the new terminal into the correct cavity at the back of the connector.

2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire.

3. To assemble the connector, reverse the connector disassembly procedure.