To the top of the document
Orlando
   
GMDE Start Page Load static TOC Load dynamic TOC Help?

Tyco/AMP Connectors - 102-Way Inline

Special Tools

    • EL-38125-580 Terminal Release Tool Kit
    • J-38125-11A Terminal Release Tool
    • J-38125-212 Terminal Release Tool
    • J-38125-216 Terminal Release Tool
    • J-38125-221 Terminal Release Tool
    • J-38125-560 Terminal Release Tool
    • J-38125-566 Terminal Release Tool

For equivalent regional tools, refer to Special Tools .

Terminal Removal Procedure


2146431

View of a typical connector in the assembled position.


    2146432
  1. Pull the locking lever to the 90 degree position from the connector body.

  2. 2146434
  3. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal.

  4. 2146435
  5. Slide the male connector body out away from the guide plates.

  6. 2146438

    Note: During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated.

  7. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body.

  8. 2146439
  9. Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.

  10. 2146440
  11. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.

  12. 2146442
  13. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.

  14. 2146443
  15. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body.

  16. 2146444
  17. Move the locking lever 180 degrees from the connected position.

  18. 2146445
  19. With the locking lever in the 180 degree position the guide plates can be removed from the connector body.

  20. 2146446

    Note: During assembly the TPA will not fully seat if any terminal is not fully seated.

  21. Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body.

  22. 2146447
  23. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity.

  24. 2146449
  25. Terminal plate will bind slightly on each corner.

  26. 2146451
  27. Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.

  28. 2146452
  29. Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.

  30. 2146453
  31. Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.

  32. 2146449
  33. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner.

  34. 2146454
  35. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever.

  36. 2146435
  37. Slide the male connector body back inward toward the guide plates.

  38. 2146434
  39. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly.

  40. 2146431
  41. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector.
  42. Repair the terminal by following the Repairing Connector Terminals : Terminated Lead Repair procedure.
  43. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.
   


© Copyright Chevrolet. All rights reserved