Volt

Tyco/AMP Connectors - 102-Way Inline

Special Tools

For equivalent regional tools, refer to Special Tools .

View of a typical connector in the assembled position.

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



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



3. Slide the male connector body out away from the guide plates.




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

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



5. 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.



6. 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.



7. 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.



8. 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.



9. Move the locking lever 180 degrees from the connected position.



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




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

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



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



13. Terminal plate will bind slightly on each corner.



14. 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.



15. 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.



16. 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.



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



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



19. Slide the male connector body back inward toward the guide plates.



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



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