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Delphi Connectors - Micro-Pack 100W

Special Tools

For equivalent regional tools, refer to Special Tools .

There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also.

The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a grey interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centreline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centreline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities.

Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area.

Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.

1. Disconnect the connector from the component.



2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such.



3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece.
4. Repeat the procedure for the other locking tab and remove the nose piece.
5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary.



6. Use fingers to squeeze the 2 locking legs of the cover.



7. Apply pressure and gently rock the cover until one locking leg is unseated.



8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover.



9. Use J-38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector.
10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector.
11. Repair the terminal by following the Repairing Connector Terminals : Terminated Lead Repair procedure.
12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.

After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals.

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 Terminal Removal Procedure.