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Repairing Connector Terminals

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Tools Required 

J-38125  Terminal Repair Kit. See Special Tools and Equipment .

Use the following repair procedures in order to repair the following:

Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125  contains further information. See Special Tools and Equipment .

  1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss.

    For cable seal terminals, remove the seal.

  2. Apply the correct cable seal per gage size of the wire, if used.

    Slide the seal back along the wire in order to enable insulation removal.

  3. Remove the insulation.
  4. For sealed terminals only, align the seal with the end of the cable insulation.
  5. Position the strip in the terminal.

    For sealed terminals, position the strip and seal in the terminal.

  6. Hand crimp the core wings.
  7. Hand crimp the insulation wings.

    For sealed terminals, hand crimp the insulation wings around the seal and the cable.

  8. Solder all of the hand crimp terminals excepting Micro-Pack 100 .64 size. Soldering Micro-Pack 100 World terminals may damage the terminal.
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