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Home >> Chevrolet >> 2020 >> Express 2500 LS, 6.0L Eng VIN G >> Repair and Diagnosis >> External Pages >> Different car >> Section 7 (Wiring Systems And Power Management - Repair Instructions) >> Repair Instructions >> Tyco/AMP Connectors (102-Way Inline) >> Terminal Removal Procedure

Terminal Removal Procedure

WARNING: This page is about a different car, the 2019 GMC Savana 3500, 2019 GMC Savana 2500, 2019 Chevrolet Express 3500, and 2019 Chevrolet Express 2500. However, it is still accessible from the selected car via links, so may be relevant.
GM2146431Courtesy of GENERAL MOTORS COMPANY

View of a typical connector in the assembled position.

  1. GM2146432Courtesy of GENERAL MOTORS COMPANY

    Pull the locking lever to the 90 degree position from the connector body.

  2. GM2146434Courtesy of GENERAL MOTORS COMPANY

    With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal.

  3. GM2146435Courtesy of GENERAL MOTORS COMPANY

    Slide the male connector body out away from the guide plates.

  4. GM2146438Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated.

    Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body.

  5. GM2146439Courtesy of GENERAL MOTORS COMPANY

    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. GM2146440Courtesy of GENERAL MOTORS COMPANY

    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. GM2146442Courtesy of GENERAL MOTORS COMPANY

    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. GM2146443Courtesy of GENERAL MOTORS COMPANY

    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. GM2146444Courtesy of GENERAL MOTORS COMPANY

    Move the locking lever 180 degrees from the connected position.

  10. GM2146445Courtesy of GENERAL MOTORS COMPANY

    With the locking lever in the 180 degree position the guide plates can be removed from the connector body.

  11. GM2146446Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    During assembly the TPA will not fully seat if any terminal is not fully seated.

    Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body.

  12. GM2146447Courtesy of GENERAL MOTORS COMPANY

    Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity.

  13. GM2146449Courtesy of GENERAL MOTORS COMPANY

    Terminal plate will bind slightly on each corner.

  14. GM2146451Courtesy of GENERAL MOTORS COMPANY

    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. GM2146452Courtesy of GENERAL MOTORS COMPANY

    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. GM2146453Courtesy of GENERAL MOTORS COMPANY

    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. GM2146449Courtesy of GENERAL MOTORS COMPANY

    Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner.

  18. GM2146454Courtesy of GENERAL MOTORS COMPANY

    With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever.

  19. GM2146435Courtesy of GENERAL MOTORS COMPANY

    Slide the male connector body back inward toward the guide plates.

  20. GM2146434Courtesy of GENERAL MOTORS COMPANY

    With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly.

  21. GM2146431Courtesy of GENERAL MOTORS COMPANY

    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) , or 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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