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Terminal Removal Procedure

Fig 1: View Of Typical Connector In Assembled Position
GM2146431Courtesy of GENERAL MOTORS COMPANY

View of a typical connector in the assembled position.

    Fig 2: View Of Locking Lever At 90 Degrees From Connector Body
    GM2146432Courtesy of GENERAL MOTORS COMPANY
  1. Pull the locking lever to the 90 degree position from the connector body.
    2. Fig 3: Assembled View Of Connector - Tyco/AMP (102-Way Inline)
    GM2146434Courtesy of GENERAL MOTORS COMPANY
  2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal.
    3. Fig 4: Sliding Male Connector Body Away From Guide Plates
    GM2146435Courtesy of GENERAL MOTORS COMPANY
  3. Slide the male connector body out away from the guide plates.
    4. Fig 5: View of Terminal Release Tool J-38125-566 and TPA
    GM2146438Courtesy of GENERAL MOTORS COMPANY
    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. Fig 6: Using Terminal Release Tool J 38125-566 to Release Lock Tabs
    GM2146439Courtesy of GENERAL MOTORS COMPANY
  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. Fig 7: Using Terminal Release Tool J-38125-221
    GM2146440Courtesy of GENERAL MOTORS COMPANY
  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. Fig 8: Releasing Lock Tabs
    GM2146442Courtesy of GENERAL MOTORS COMPANY
  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. Fig 9: View Of Female Connector Body - Tyco/AMP (102-Way Inline)
    GM2146443Courtesy of GENERAL MOTORS COMPANY
  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. Fig 10: Moving Locking Lever 180 Degrees
    GM2146444Courtesy of GENERAL MOTORS COMPANY
  9. Move the locking lever 180 degrees from the connected position.
    10. Fig 11: Removing Guide Plates From Connector Body
    GM2146445Courtesy of GENERAL MOTORS COMPANY
  10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body.
    11. Fig 12: Removing TPA
    GM2146446Courtesy of GENERAL MOTORS COMPANY
    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. Fig 13: Lifting Terminal Plate Past Terminals
    GM2146447Courtesy of GENERAL MOTORS COMPANY
  12. Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity.
    13. Fig 14: View Of Terminal Plate
    GM2146449Courtesy of GENERAL MOTORS COMPANY
  13. Terminal plate will bind slightly on each corner.
    14. Fig 15: View of Using Terminal Release Tool J 38125-221 to Release Lock Tabs
    GM2146451Courtesy of GENERAL MOTORS COMPANY
  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. Fig 16: View of Pressing Prongs On Each Side Of Terminal Using J 38125-212
    GM2146452Courtesy of GENERAL MOTORS COMPANY
  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. Fig 17: Pressing Prongs On Each Side Of Terminal - Tyco/AMP (102-Way Inline)
    GM2146453Courtesy of GENERAL MOTORS COMPANY
  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. Fig 18: View Of Terminal Plate
    GM2146449Courtesy of GENERAL MOTORS COMPANY
  17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner.
    18. Fig 19: Aligning Guide Plates To Mesh With Locking Lever Gears
    GM2146454Courtesy of GENERAL MOTORS COMPANY
  18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever.
    19. Fig 20: Sliding Male Connector Body Away From Guide Plates
    GM2146435Courtesy of GENERAL MOTORS COMPANY
  19. Slide the male connector body back inward toward the guide plates.
    20. Fig 21: Assembled View Of Connector - Tyco/AMP (102-Way Inline)
    GM2146434Courtesy of GENERAL MOTORS COMPANY
  20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly.
    21. Fig 22: View Of Typical Connector In Assembled Position
    GM2146431Courtesy of GENERAL MOTORS COMPANY
  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) , Repairing Connector Terminals (Terminal Repair)  procedure.
  23. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.
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