Contacts in Terminal Housing, Repairing

Fig 1: Releasing Terminal Lock And Pulling Wire With Single Wire Seal Toward Rear Out Of Terminal Housing

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Procedure

First, open or release secondary lock of the contact housing (where applicable) → Terminal Housings, Releasing and Disassembling .

Release contact (primary lock) using appropriate release tool - A - → Terminal Housings, Releasing and Disassembling .

Pull contact back out of housing - arrow - at single wire (with single wire seal if necessary).

Fig 2: Cutting Off Old Terminal With Single Wire Seal

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut off old contact (with the single wire seal) from vehicle-specific wiring harness.

Determine yellow repair wire with correct contact from Wiring Harness Repair Set VAS 1978A.

Free up wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION: Risk of damaging the electrical wires.

Fig 3: Inserting New Terminal Into Terminal Housing

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Slide new repair wire contact into corresponding contact housing compartment until it engages.

If necessary, install single wire seal on repair wire → Single Wire Seals, Assembly .

Fig 4: Cutting Wire Using Side-Cutter Function Of Wire Stripper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Shorten repair wire and vehicle-specific wiring harness single wire as needed using the Wire Stripper VAS 1978/3.

Remove insulation from ends of repair wire and vehicle-specific single wire and crimp ends with crimping wires and a crimp connector → Wire, 0.25 mm with Individual Crimp Connector, Repairing or → Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing .