Harley Davidson 2018 softail models. Service manual — page 49
The teeth on the locking bar face down.
3. Slide the locking bar onto the connector.
Figure 2. Tangs: Bosch Compact 1.1M Terminal
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. DO NOT re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
PACKARD TERMINAL CRIMP
HD-38125-6
1
TOOL
Delphi GT 150 connectors are typically used on fuel injectors, ignition coil and VSS. The GT 280 sealed connectors are
used to connect to the fuel pump and sender.
See Figure 1. The plug assembly consists of housing with connector cavities, terminals, secondary lock, wire seals, safety
lock, mating seal and primary lock.
NOTE
Use PACKARD TERMINAL CRIMP TOOL (Part Number:HD-38125-6) for Delphi GT sealed terminal crimping. Refer
to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 2. Press connector release (A), separate the two halves (B).
Mating Connector
Push the halves of connector together until external latch(es) engage.
1
Secondary lock
2
GT 280 female terminals
3
Connector housing 2-way
4
Seal
5
Primary lock
Figure 1. Exploded View
1
Connector housing
2
Connector release
Figure 2. Disconnect
Terminal Removal
1. See Figure 3. Using TERMINAL EXTRACTOR (Part Number:B-50085), completely remove the primary lock.
2. Release the two locks and remove the secondary lock.
3. From the front of the cavity, locate the terminal lock. Insert the removal tool straight into the cavity, deflect the
terminal lock and release the terminal. Gently pull on the wire to remove terminal from the connector.
1
Primary lock
2
Removing secondary lock
3
Removal tool
4
Terminal lock
5
Terminal
6
Connector housing
Figure 3. Terminal Removal
Installing Terminals
1. See Figure 4. Insert the primary lock into the outer most position on the connector.
NOTE
Proper orientation of terminal required.
2. Insert terminals into connector housing.
3. Insert secondary lock onto cavity until locked.
4. Install primary lock until it is locked in position.
1
Primary lock
2
Terminal
3
Secondary lock
4
Primary lock
Figure 4. Terminal Installation
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
PACKARD TERMINAL CRIMP
HD-38125-6
1
TOOL
PACKARD TERMINAL CRIMPER
HD-38125-7
1
There are two types of connectors in this series:
Pull-to-Seat
Push-to-Seat
NOTE
Use PACKARD TERMINAL CRIMP TOOL (Part Number:HD-38125-6) for push-to-seat Delphi Metri-Pack
terminal crimping.
Use PACKARD TERMINAL CRIMPER (Part Number:HD-38125-7) for pull-to-seat Delphi Metri-Pack terminal
crimping.
Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
Pry up on the external latch slightly and separate the connector.
Mating Connector
Push the halves of the connector together.
Terminal Removal Push-to-Seat
NOTE
The same process is followed for both the male and female ends of the push to seat connectors.
For best results, free one side of the secondary lock first and then release the other side.
1. See Figure 1. Remove secondary lock from wire end of connector.
2. Find the locking tang in the mating end of the connector.
NOTE
The tangs are always positioned in the middle of the cavity on the same side as the external latch.
There is a small opening for the pin.
3. Gently insert a small diameter straight pin into the cavity about 3.2 mm (⅛ in).
NOTE
The click is the sound of the tang returning to the locked position as it slips from the point of the pin.
4. Pick at the tang until the clicking stops and the pin seems to slide in deeper. This indicates the tang is pressed
in.
5. Pull on the lead to draw the terminal out the wire end.
1
Remove wire lock
2
Pivot pin to release tang
3
Pull to remove
4
Raise tang to install
Figure 1. Removing Delphi Metri-Pack Sealed Connector: Push-to-Seat
Terminal Removal Pull-to-Seat
NOTE
The tangs are always positioned in the middle of the cavity. The tangs are on the same side as the external latch.
1. See Figure 2. Find the locking tang in the mating end of the connector.
NOTE
Stay between the terminal and the cavity wall and pivot the end of the pin toward the terminal body.
2. Gently insert a small diameter straight pin into the cavity about 3.2 mm (⅛ in).
NOTE
The click is the sound of the tang returning to the locked position as it slips from the point of the pin.
3. When a click is heard, remove the pin and repeat the procedure.
NOTE
After repeated terminal extractions, the click may not be heard, but pivot the pin as if the click was heard at least
three times.
4. Pick at the tang until the clicking stops and the pin seems to slide in deeper. This indicates the tang is pressed
in.
5. Push on the lead to extract the terminal from the mating end of the connector.
1
Locate tang in cavity
2
Pivot pin to release tang
3
Push to remove
4
Raise tang to install
Figure 2. Delphi 150.2 Metri-Pack Sealed Connector: Pull-to-Seat
Installing Terminal Push-to-Seat
1. See Figure 3. Plug terminals into connector assembly.
2. After all leads are plugged, install secondary lock to connector.
a. Hold connector as shown and install secondary lock.
b. Position secondary locks with corresponding grooves and verify one lead per cavity. Apply pressure
with fingers until secondary lock snaps into place.
1
Insert terminals into connector
2
Install secondary lock
3
Locked
Figure 3. Insert Terminals Push-to-Seat
Installing Terminal Pull-to-Seat
NOTE
Leads must be blunt cut for this operation.
1. See Figure 4. Push wire leads through cable seal at least 203 mm (8 in).
2. Strip each wire lead to the required length for the terminal being applied.
3. Crimp terminals on wire ends
4. Align the terminals with the locating tabs in the cavity and pull wires back through connector to install the
terminal.
5. Verify terminal is fully seated in the terminal cavity.
1
Push wire leads through cable seal
2
Strip each wire lead
3
Crimp terminals on wire ends
4
Pull wires back through connector
5
Verify terminal is fully seated
Figure 4. Inserting Terminal Pull-to-Seat
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
PACKARD MICRO-64 TERMINAL
HD-45928
1
REMOVER
PACKARD MICRO-64 TERMINAL
HD-45929
1
CRIMPER
Delphi Micro 64 Sealed connectors are frequently found on speedometers and tachometers.
NOTE
Use PACKARD MICRO-64 TERMINAL CRIMPER (Part Number:HD-45929) for Delphi Micro 64 terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
Bend back the external latches slightly and separate the connector.
Mating Connector
Align the terminals and press the connector together until the latch snaps.
Terminal Removal
1. See Figure 1. Locate the head of the secondary lock on one side of the connector housing.
2. Insert the blade of a small screwdriver between the center ear of the lock and the connector housing and gently
pry out lock. When partially removed, pull lock from connector housing.
3. Locate pin hole between terminals on mating end of connector.
1
Stamped number
2
Pin hole
3
Secondary lock
4
Insert terminal remover
5
Remove terminal
Figure 1. Terminal Removal
4. Obtain the PACKARD MICRO-64 TERMINAL REMOVER (Part Number:HD-45928).
5. Push the adjacent terminals all the way into the connector housing and then insert tool into hole until it bottoms.
6. Leaving the tool installed, gently tug on wires to pull either one or both terminals from wire end of connector.
Remove tool.
Installing Terminal
1. Insert terminal into its respective numbered cavity on wire end of connector. No special orientation of the
terminal is necessary.
NOTE
For wire location purposes, the corners of the connector are stamped with the numbers 1, 6, 7 and 12,
representing terminals 1-6 on one side, and 7-12 on the other.
2. Bottom the terminal in the cavity and then gently tug on the wire to verify that it is locked in place.
NOTE
Once removed, the terminal may not lock in place when first installed. Until the lock engages, move the terminal
back and forth slightly while wiggling the lead.
3. Since the terminal remover tool releases two terminals simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4. With the center ear on the head of the secondary lock facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
DEUTSCH CRIMPER
HD-39965-a
1
DEUTSCH CONNECTOR SERVICE
HD-41475
1
KIT
FLAT BLADE L-HOOK
HD-41475-100
1
ELECTRICAL CRIMPER TOOL
HD-42879
1
A DEUTSCH CONNECTOR SERVICE KIT (Part Number:HD-41475) contains a selection of seals and seal plugs, locking
wedges, attachment clips and terminals. Also included is a FLAT BLADE L-HOOK (Part Number:HD-41475-100) used to
remove locking wedges, compartmented storage box and carrying case.
NOTE
Use the DEUTSCH CRIMPER (Part Number:HD-39965-a) for non-solid barrel terminal crimping.
Use the ELECTRICAL CRIMPER TOOL (Part Number:HD-42879) for solid barrel terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 1. To separate the connector halves, press the external latch(es) on the connector while rocking the
connector halves, and pull.
NOTE
Six-place and smaller Deutsch connectors have one latch on the connector.
Eight- and twelve-place connectors have a latch on each side. Simultaneously press both latches to separate
the connector.
Mating Connector
1. Align the connectors to match the wire lead colors.
a. For One External Latch: To join the halves, align the latch on the socket side with the latch cover on
the pin side.
b. For Two External Latches: Align the tabs on the connector halves.
NOTE
For Two External Latches: If latches do not click (latch), press on one side of the connector until that latch
engages then press on the opposite side to engage the other latch.
2. Insert the two halves together until it locks into place.
1
External latch
2
Socket housing
3
Pin housing
Figure 1. Deutsch DT Sealed Connector
Terminal Removal
1. See Figure 2. Remove wedgelock using needlenose pliers or removal tool.
2. To remove the terminals, gently pull wire backwards, while at the same time releasing the locking finger by
moving it away from the terminal with a screwdriver.
3. Hold the rear seal in place when pulling terminal/wire out, as removing the terminal may displace the seal.
1
Remove wedgelock
2
Releasing locking finger
3
Locking finger
4
Remove terminal
Figure 2. Terminal Removal
Installing Terminal
NOTE
The receptacle is shown. Use the same procedure for plug.
1. See Figure 3. Grasp terminal approximately 25.4 mm (1 in) behind the terminal barrel.
2. Push terminal straight into connector grommet until a click is felt.
3. Gently pull on the wire to confirm that it is properly locked in place.
4. Once all terminals are in place, insert wedgelock. The wedgelock will snap into place.
1
Grasp terminal
2
Hold connector
3
Insert terminal
4
Insert wedgelock
Figure 3. Inserting Terminals
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
HAND CRIMP FRAME
HD-50120-2
1
JAE DIE
HD-50120-6
1
The plug assembly consists of a wire seal (part of housing), housing and two terminals.
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with JAE DIE (Part Number:HD-50120-6) for JAE MX19
series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 1. Press the latch while pulling the connector halves apart.
Figure 1. Release Button
Mating Connector
Align the terminals and press the connectors together until the latch snaps.
Terminal Removal
1. Modify a TERMINAL EXTRACTOR (Part Number:B-50085) by filing the front edge to 45 degrees.
2. See Figure 2. Insert the extractor into the opening above the terminal and press the plastic molding up and out
of the way.
3. Pull the wire lead and terminal out of the back of the connector.
1
Terminal extractor
2
Connector
Figure 2. Terminal Removal
Installing Terminal
1. Inspect the connector housing and replace if necessary.
2. Orient the terminal to the housing. Push terminal into housing until it clicks into place.
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
DIE SET
HD-50120-11
1
HAND CRIMP FRAME
HD-50120-2
1
The plug assembly consists of a wire seal (part of housing), housing, yellow secondary, two terminals, and one red mating
seal. The mating seal provides a tight closure for mated connectors.
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with DIE SET (Part Number:HD-50120-11) for JST JWPF
series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 1. Press locking lever on female housing. Pull connector halves apart.
Mating Connector
1. Align the connectors so the latches line up.
2. Press together until locked.
Figure 1. Locking Lever: JST JWPF Sealed Connector
Terminal Removal
1. See Figure 2. Locate large openings on the front of the connector housing.
2. Insert TERMINAL EXTRACTOR (Part Number:B-50085) into large openings and release retention finger that
locks terminal in place.
3. Remove terminal.
1
Openings for removal tool
2
Terminal
3
Connector housing
4
Terminal extractor
5
Removing terminal
Figure 2. Terminal Removal
Installing Terminal
1. Inspect connector housing and replace if necessary.
2. Orient the terminal to the housing. Push terminal into housing until it clicks into place.
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
HAND CRIMP FRAME
HD-50120-2
1
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with HD-50120-12 (DIE SET) for Kostal MLK 1.2 series
terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
1. See Figure 1. Lift the locking clip up in the unlocked position.
2. Press the locking clip in and release.
3. Pull and separate the two halves.
1
Locking clip in locked position
2
Lift locking clip to the unlocked position
3
Press locking clip and lift connector to separate
Figure 1. Separating Connector
Mating Connector
1. See Figure 2. Push the halves of connector together until they click.
2. Push the locking clip down into locked position.
1
Push connectors together
2
Listen for click
3
Push safety lock down
Figure 2. Mating Connector
Terminal Removal
1. See Figure 3. Using a screwdriver, insert in hole in side of protective Housing and release the secondary lock.
2. Insert TERMINAL EXTRACTOR (Part Number:B-50085) into opening over terminal.
3. The terminal can be removed by pulling on the wire while simultaneously applying light pressure to disengage
the primary lock.
1
Secondary lock in locked position
2
Insert screwdriver and release secondary lock
3
Secondary lock in unlocked position
4
Opening over terminal
5
Terminal extractor
6
Primary lock
7
Secondary lock
8
Push terminal extractor into opening over terminal
9
Remove terminal
Figure 3. Terminal Removal
Installing Terminal
NOTE
Proper orientation of terminal required.
1. See Figure 4. Insert female terminals into receptacle connector until an audible click is heard or lock is felt
2. Using a screwdriver, insert in hole in side of protective Housing and using a slight force push secondary lock
into locked position.
1
Terminal
2
Primary lock
3
Secondary lock in unlocked position
4
Insert screwdriver and push secondary lock into
locked position
5
Secondary lock in locked position
Figure 4. Installing Terminal
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
HAND CRIMP FRAME
HD-50120-2
1
JAE DIE
HD-50120-3
1
JAE DIE
HD-50120-4
1
0.6 MM TERMINAL EXTACTOR
HD-50423
1
TOOL
1.5 MM TERMINAL EXTRACTOR
HD-50424
1
TOOL
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with JAE DIE (Part Number:HD-50120-3) for 18-16 gauge or
JAE DIE (Part Number:HD-50120-4) for 20-18 gauge Molex CMC series terminal crimping. Refer to Bosch tool
instruction sheet for crimping instructions.
Separating Connector
See Figure 1. Press the catch and rotate the lever arm down.
Figure 1. Release
Mating Connector
1. Align the connector.
2. Rotate the lever arm up until the catch clicks in place.
Terminal Removal
1. With the lever arm open, cut the cable strap around the wire bundle.
2. See Figure 2. Open a wire cap latch with a small screwdriver.
3. Maintain pressure on the cap and open the opposite latch with the screwdriver.
4. Slide the cap off.
5. Use the screwdriver to open the secondary lock. Pull the locking bar all the way out.
6. Locate the wire lead cavity by the alpha-numeric coordinates.
7. Identify the size of the terminal and select either the CMC extractor 0.6 MM TERMINAL EXTACTOR TOOL
(Part Number:HD-50423) or the 1.5 MM TERMINAL EXTRACTOR TOOL (Part Number:HD-50424).
8. Insert the pins of the CMC extractor tool into the access slots of the terminal cavity and retract the lead and
terminal.
1
Press latch
2
Press cap and latch
3
Remove wire lead cap
4
Remove secondary lock
5
Extractor tool
6
Access slots
Figure 2. Terminal Removal
Installing Terminal
1. Orient the terminal to the housing cavity. Snap the terminal in place.
2. Slide the cap over the lead bundle. Snap the cap in place.
3. Install a cable strap through the guide and around the lead bundle.
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
MOLEX ELECTRICAL
HD-48114
1
CONNECTOR TERMINAL
REMOVER
ELECTRICAL CRIMP TOOL
HD-48119
1
DIE SET
HD-50120-11
1
HAND CRIMP FRAME
HD-50120-2
1
NOTE
Use ELECTRICAL CRIMP TOOL (Part Number:HD-48119) for Molex MX150 terminal crimping.
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with DIE SET (Part Number:HD-50120-11) for Molex
MX64 series terminal crimping.
Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
See Figure 1. Press the latch while pulling the connector halves apart.
Mating Connector
1. Align the connectors so the latches line up.
2. Press together until locked.
Figure 1. Molex MX 150 Sealed Connector Latch
Terminal Removal (Male Terminals)
NOTE
The secondary lock should never be fully removed from the connector. Excessive force may damage the
secondary lock.
Do not apply any lateral force. This may damage the tool or the locking finger.
Excessive force can damage the lock finger.
Do not insert the service tool at an angle. This may cause damage to the terminal.
Do not insert the removal tool into the terminal opening.
1. See Figure 2. Insert a small pair of needle nose pliers in the removal holes.
2. Pull back gently 5 mm (0 in) until the secondary lock is unlocked.
3. Using the MOLEX ELECTRICAL CONNECTOR TERMINAL REMOVER (Part Number:HD-48114), insert the
tip into the terminal service ports adjacent to the terminal cavity to be removed.
4. Apply downward pressure to release the lock and remove the wire. If the terminal resists, the removal tool may
not be fully engaged. Verify that it has fully disengaged the lock.
1
Pull up secondary lock
2
Service ports
3
Insert removal tool
Figure 2. Terminal Removal: Male
Terminal Removal (Female Terminals) MX150 Series
NOTE
The secondary lock should never be fully removed from the connector housing. Excessive force may damage
the secondary lock.
Do not apply any lateral force. This may damage the tool or the locking finger.
Excessive force can damage the lock finger.
Do not insert the service tool at an angle. This may cause damage to the terminal.
Do not insert the removal tool into the terminal opening.
1. See Figure 3. Insert a small screwdriver into the secondary lock release.
2. Using the housing as a pivot point gently pry out on the secondary lock to unlock.
3. Using the MOLEX ELECTRICAL CONNECTOR TERMINAL REMOVER (Part Number:HD-48114), insert the
tip into the terminal service ports adjacent to the terminal cavity to be removed.
4. Apply downward pressure to release the lock and remove the wire. If the terminal resists, the removal tool may
not be fully engaged. Verify that it has fully disengaged the lock.
1
Pry up secondary lock
2
Service ports
3
Insert removal tool
Figure 3. Terminal Removal: Female
Terminal Removal (Female Terminals) MX64 Series
1. See Figure 4. Using a small blade screwdriver pry up on the secondary lock and remove.
NOTE
Do not use excessive force. Excessive force can damage the lock finger.
2. Using a small blade screwdriver, release the terminal lock. Gently pull on the wire to remove the terminal.
1
Remove secondary lock
2
1 mm pry tool
3
Pry point for terminal lock
4
Primary lock
Figure 4. Removing Terminals in MX64 Series Connector
Installing Terminal
1. See Figure 5. With secondary lock unlocked, align the terminal to rear of connector.
2. Insert the terminal until it stops and locks on the lock finger with an audible click.
3. See Figure 5.
a. On the MX64, install and lock the secondary lock.
b. On the MX150, push to lock the secondary lock.
1
MX 64 series
2
MX 150 series
Figure 5. Terminal Installation
Replacement and Repair
The terminals and connector assemblies are not repairable. Discard and replace any defective or damaged terminals
or connector assemblies. Do not re-use a terminal by removing the wire.
Special Tools
Description
Part Number
Qty.
ROBINAIR HEAT GUN
HD-25070
1
PACKARD CRIMPING TOOL
HD-38125-8
1
ULTRA TORCH UT-100
HD-39969
1
HEAT SHIELD ATTACHMENT
HD-41183
1
NOTE
Refer to Bosch tool instruction sheet for crimping instructions.
Splice connectors and several OEM ring terminal connectors use heat shrink covering to seal the connection.
Preparing Wire Leads
NOTE
When splicing adjacent wires, stagger the splices so the sealed splice connectors will not touch each other.
1. Using a shop gauge, identify the gauge of the wire.
2. Match the wire gauge to a sealed splice connector by color and part number. Refer to Table 1.
3. Strip insulation off the wire lead. Refer to Table 1.
Table 1. Sealed Splice Connectors
WIRE GAUGE
COLOR
PART NO.
STRIP LENGTH
IN
MM
18-20 (0.5-0.8 mm)
Red
70585-93
3/8
9.5
14-16 (1.0-2.0 mm)
Blue
70586-93
3/8
9.5
10-12 (3.0-5.0 mm)
Yellow
70587-93
3/8
9.5
NOTE
If any copper wire strands are cut off of the wire core, trim the end and strip the wire again in a larger gauge
stripper.
Splicing Wire Leads
NOTE
The connector is crimped on one side and then the other.
1. See Figure 1. Open the PACKARD CRIMPING TOOL (Part Number:HD-38125-8) ratchet by squeezing the
handles closed.
2. Match the connector color to the wire gauge crimp die in the jaws. Insert one end of the sealed connector.
3. Gently squeeze the handles until the connector is held in the jaws.
4. See Figure 2. Feed the stripped end of a wire into the connector until the wire stops inside the metal insert.
5. Squeeze the handles tightly closed to crimp the lead in the insert. The tool automatically opens when the
crimping is complete.
6. Slide the connector to the other half of the metal insert. Insert the stripped wire lead until it stops. Crimp the
lead in the insert.
WARNING
Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating
device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury.
(00335a)
Avoid directing heat toward any electrical system component that is not being serviced.
Always keep hands away from tool tip area and heat shrink attachment.
NOTE
It is acceptable for the splice to rest against the heat shrink tool attachment.
7. Use an ULTRA TORCH UT-100 (Part Number:HD-39969), or a ROBINAIR HEAT GUN (Part Number:HD-
25070) with a HEAT SHIELD ATTACHMENT (Part Number:HD-41183), to heat the connector from the center
of the crimp out to each end.
1
Red connector die
2
Blue connector die
3
Yellow connector die
Figure 1. Packard Crimping Tool (HD-38125-8)
Inspecting Seals
See Figure 2. Allow the splice to cool and inspect the seal. The insulation should appear smooth and cylindrical.
Melted sealant will have extruded out the ends of the insulation.
1
Wire lead in metal insert
2
Crimp metal insert
3
Center of crimp
4
Melted SEALANT
Figure 2. Sealed Splice Connector
Special Tools
Description
Part Number
Qty.
TERMINAL EXTRACTOR
B-50085
1
HAND CRIMP FRAME
HD-50120-2
1
TYCO GET 64 DIE
HD-50120-7
1
NOTE
Use HAND CRIMP FRAME (Part Number:HD-50120-2) with TYCO GET 64 DIE (Part Number:HD-50120-7) for Tyco
GET 64 series terminal crimping. Refer to Bosch tool instruction sheet for crimping instructions.
Separating Connector
1. See Figure 1. Pull the latch lock open.
2. While pressing the connector latch, pull the connector apart.
Mating Connector
1. Align the connector housings.
2. Press the housings together.
3. Push the latch lock closed.
1
Latch lock (open)
2
Latch lock (closed)
3
Connector latch
Figure 1. Tyco GET 64 Sealed Connector Latch and Lock
Terminal Removal
1. See Figure 2. Remove secondary lock from the connector.
2. Insert TERMINAL EXTRACTOR (Part Number:B-50085) into the cavity next to the terminal.
3. Pry and hold the tang away from the terminal.
4. Pull on the wire lead to remove the terminal.
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