Push-to-Seat Connectors

NOTE: The following general repair procedures can be used to repair most types of connectors. Use the Pick(s) or Tools that apply to your terminal. Use Terminal repair kit J 38125 or equivalent.

Figure 1 - Typical Push-To-Seat Connector:

Follow the steps below to repair Push-To-Seat connectors (Figure 1). The steps are illustrated with typical connectors. Your connector may be different, but the repair steps are similar. Some connectors DO NOT require all the steps shown. Skip the steps that DO NOT apply.

1. Remove Terminal Position Assurance (TPA) device, Connector Position Assurance (CPA) device and/or secondary lock. Separate connector halves (see Figures 2 through 6).

Figure 2:

Figure 3:

Figure 4:

Figure 5:

Figure 6:

2. Release terminal using proper pick or removal tool. Gently pull cable and terminal out the back of the connector (see Figures 7 through 11).

Figure 7:

Figure 8:

Figure 9:

Figure 10:

Figure 11:

3. If terminal is to be re-used, re-form locking tang (see Figures 12 through 16).

Figure 12:

Figure 13:

Figure 14:

Figure 15:

Figure 16:

4. Making repair when using a new terminal:
a. Slip cable seal away from terminal (if seal exist).
b. Cut wire as close to terminal as possible.
c. Slip a new cable seal onto wire (if necessary).
d. Strip 5 mm (3/16") of insulation from wire.
e. Crimp a new terminal to the wire.
f. Solder with rosin core solder.
g. Slide cable seal toward terminal (if equipped with seal).
h. Crimp cable seal and insulation (if equipped with seal).
i. Apply grease to connectors outside passenger compartment where connector was originally equipped with grease.

Figure 17:

To re-use a terminal or lead assembly, see previous steps c through i for repairs. Be sure to keep cable seal (if equipped) on terminal side of splice.

5. Insert lead from the back until it catches.
6. Install TPA's, CPA's and/or secondary locks, if equipped (see Figures 18 & 19).