Repairing Connector Terminals

REPAIRING CONNECTOR TERMINALS

TOOLS REQUIRED
J 38125-D Terminal Repair Kit

Use the following repair procedures in order to repair the following:
- Push to Seat terminals
- Pull to Seat terminals
- Weather Pack(R) terminals

Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-D contains further information.

1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.
For Weather Pack(R) terminals, remove the seal.
2. Apply the correct seal per gage size of the wire.
For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation.
4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation.
5. Position the strip in the terminal.
For Weather Pack(R) terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings.
7. Hand crimp the insulation wings.
For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal.