Hummer H2. Manual — part 1350

Fig. 21: Aligning Locking Device
Courtesy of GENERAL MOTORS CORP.

5. Re-form the locking device if you are going to reuse the terminal (1).

6. To repair the terminal, refer to Terminal Repair.

Terminal Repair

1. Slip the cable seal away from the terminal.

2. Cut the wire as close to the terminal as possible.

3. Slip a new cable seal onto the wire.

4. Strip 5 mm (3/16 in) of insulation from the wire.

5. Crimp a new terminal to the wire.

6. Solder the crimp with rosin core solder.

7. Slide the cable seal toward the terminal.

8. Crimp the cable seal and the insulation.

9. If the connector is outside of the passenger compartment, apply grease to the connector.

Reinstalling Terminal

1. In order to reuse a terminal or lead assembly. Refer to Wiring Repairs .

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

2. Ensure that the cable seal is kept on the terminal side of the splice.

3. Insert the lead from the back until it catches.

4. Install the TPA, CPA and/or the secondary locks.

PULL TO SEAT CONNECTORS

Terminal Removal

If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced.

Follow the steps below in order to repair pull-to-seat connectors:

Fig. 22: Aligning Removal Tool
Courtesy of GENERAL MOTORS CORP.

1. Remove the connector position assurance (CPA) device and/or the secondary lock.

2. Disconnect the connector from the component or separate the connectors for in-line connectors.

3. Remove the terminal position assurance (TPA) device.

4. Insert the proper pick or removal tool into the front of the connector body.

5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the

IMPORTANT: On connectors with more than one terminal the service loop may not be

large enough to remove the terminal and crimp on a new one. If the
terminal wire does not have a large enough service loop for removal, cut
the wire 5 cm (2 in) behind the connector before removal.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

connector body (3).

Terminal Repair

1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size

wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a
new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible.

2. Strip 5 mm (3/16 in) of insulation from the wire.

3. Crimp a new terminal to the wire.

4. Solder the crimp with rosin core solder.

Terminal Installation

1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal.

2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper

Wire Using Splice Sleeves .

3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector.

4. Install the TPA, CPA and/or the secondary locks.

MICRO-PACK 100W CONNECTORS

Terminal Removal Procedure

1. Disconnect the connector from the component or separate the connector halves for in-line connectors.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

Fig. 23: Locating Nose Piece Locking Tabs
Courtesy of GENERAL MOTORS CORP.

2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2