Operating Procedures For Repairs

Proceed as follows

The following chapter is arranged as follows
Using the information in this chapter most housings can be opened and the cable terminals replaced.
Note that the stages in the operations can be used with most housings/cable terminals and that the illustrations only show a few individual types as examples. Other types can occur.
The basic instructions for the repair/replacement of cable terminals are only a summary of the contents of the manual, with references to respective operations.

Caution! Note the contents of Important Important Repair work Repair Work , these instructions must be followed before carrying out any repair work.

Warning! SRS No cable repair or other repair work may be carried out on the SRS wiring.

Basic procedures for repair operations

Opening a connector




Separate the connector Separate the Connector
If the connector halves are connected they must first be opened.

Caution! Never pull the cables when opening the connector. Hold the connector halves.

Open the housing




Secondary locking Secondary Locking
Opening a housing's secondary locking.

Select terminal removal tool




Using terminal removal tools Using Terminal Removal Tools
Select the terminal removal tool that matches the housing's cavity openings.
Remove the cable terminal from the housing
Use the recommended terminal removal tool and follow the operating procedure described.

Select a new cable terminal




New cable terminal New Cable Terminal

Select a new cable terminal of the same type as the existing terminal. Use the cable terminals in the repair kit p/n 981 4235 Replaced by 9512644 981 4235 Replaced by 951 2644. Refer to the wiring diagram for information on the cable area.

SWS (Single Wire Seal)




Seal sws and plug Seal SWS and Plug
If a seal is to be used on the cable terminal thread the seal on to the cable before stripping the insulation on the cable.

Strip the cable




Cutting and checking a cable Cutting and Checking a Cable Stripping the cable Stripping the Cable
Cut and strip the cable to a length that matches the cable terminal.

Select a suitable crimp tool for the cable terminal




Choice of crimp tool Choice of Crimp Tool
Refer to information on which tool is used for which type of cable terminal.

Crimp the cable terminal
Crimping a cable terminal Crimping a Cable Terminal
Place the cable terminal in the crimp tool jaws, in the profile that matches the cable area of the cable.
Position the cable in the cable terminal.
Crimp the cable terminal on to the cable end.

Checking crimping of a cable terminal




Examples of correct terminal crimping Examples of Correct Terminal Crimping Examples of incorrect crimping Examples of Incorrect Crimping
Always check the result of the crimping operation and that the primary locking is not damaged.

Insert the cable terminal in the housing




When cable terminal is to be inserted in a housing When Cable Terminal Is to Be Inserted In A Housing
Insert the cable terminal in the appropriate cavity until the primary locking activates.
Check that the cable terminal is properly locked by pulling lightly on the cable.

Close the housing




Closing the housing Closing the Housing
The housing's secondary locking must be closed.