Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also.

The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities.

Fig 1: Identifying Micro-Pack 100W First & Second Connector Designs

GM1364951

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area.

Fig 2: Identifying Micro-Pack 100W Short & Long Terminals

GM1364942

Courtesy of GENERAL MOTORS CORP.

Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide.

Disconnect the connector from the component.

Fig 3: Locating Nose Piece Locking Tabs

GM880994

Courtesy of GENERAL MOTORS CORP.

Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such.
Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece.

Fig 4: Loosening Nose Piece Locking Tabs

GM881004

Courtesy of GENERAL MOTORS CORP.

Repeat the procedure for the other locking tab and remove the nose piece.
Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary.
Use fingers to squeeze the 2 locking legs of the cover.

Fig 5: Squeezing Cover Locking Legs

GM881006

Courtesy of GENERAL MOTORS CORP.

Apply pressure and gently rock the cover until one locking leg is unseated.

Fig 6: Unseating Locking Leg

GM881008

Courtesy of GENERAL MOTORS CORP.

Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover.

Fig 7: Removing Cover

GM881011

Courtesy of GENERAL MOTORS CORP.

Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector.

Fig 8: Identifying Terminal Retaining Tab

GM881017

Courtesy of GENERAL MOTORS CORP.