Information on Changes to the SI Table of Contents, Electrical Connectors, Terminal Testing/Repair, and the Importance of J-38125 Electrical Terminal Repair Kit Maintenance (06-08-45-001)

Publication date: 2006-02-17
Reference number: 06-08-45-001

Information on Changes to the SI Table of Contents, Electrical Connectors, Terminal Testing/Repair, and the Importance of J-38125 Electrical Terminal Repair Kit Maintenance

TECHNICAL SERVICE BULLETIN

Reference Number(s): 06-08-45-001, Date of Issue: February 17, 2006

Affected Model(s):

2007 and Prior GM Cars and Trucks; 2003-2007 HUMMER H2; 2006-2007 HUMMER H3

The J-38125 Terminal Repair Kit

The J-38125 Terminal Repair Kit is one of the most important essential tools in your dealership. This set of six gray cabinets must continually contain all of the varied terminals currently in use by GM vehicles. Over the past few years and even now, many new types of terminals and connection systems have been introduced. With these new connection systems, come new terminals and repair tools and the potential for improper servicing, if incorrect tools and methods are applied.

Why This is so Important to Every Dealer

At this point in time, GMSPO has put an order restriction on several large harnesses (e.g. I/P and Body as well as some others). If a harness order is approved, in many cases it can take 12 to 28 weeks for a harness to be built and delivered to a Dealer. The Dealer Technician is expected to repair any harness damage as the first and best choice before attempting to order any harness.

GMSPO stocks connectors, pigtails, harness conduit, tape and wire in various colors and sizes. The J-38125 Terminal Kit plays an integral part in all this because it contains not only service terminals, but the tools to make these repairs. The Connector Parts Tray contains a selection of TPAs that are otherwise unavailable from GMSPO. The SIR/SRS Tray contains terminated leads and CPAs used on the connectors for those systems.

Once a year, the J-38125 Terminal Repair Kit is updated. At this time, you are supplied with new labels for the terminal trays that have undergone any change in that trays terminal content. It is vital that you carry out these incremental updates to the terminal kit within the year of that updates arrival. Likewise, it is imperative that you stock the terminal repair kit with components supplied by SPX/Kent Moore. These terminals are your assurance that a repair will remain corrosion free and tight. The terminals found in the kit are plated with various surfaces such as tin, copper and gold. This is to assure OEM quality, with the right contact for the right application. You may reach SPX/Kent-Moore at 1-800-GM-TOOLS (1-800-468-6657) or a company called Barnes Distribution (866-438-6767), who is also an official distributor of authentic GM service terminals.

IMPORTANT: It is imperative that you stock the terminal repair kit with components supplied by SPX/Kent Moore or Barnes. The terminals found in the kit are plated with various surfaces such as tin, copper and gold. This is to assure OEM quality, with the right contact for the right application. There may be some aftermarket terminal suppliers who may sell terminals of less than OEM quality. Refer to Bulletin Number 02-00-89-017A or later for warranty information regarding terminals.

Shipped with each year's J-38125 Terminal Repair Kit update is also an updated Instruction Manual (J-38125-620C) that contains pictures of various connectors and the instructions for removing the terminals from that connector. This Manual also contains the current inventory for the J-38125 Terminal Repair Kit as well as terminal crimp information. Extra copies of this Manual are available from SPX/Kent-Moore at 1-800-GM-TOOLS (1-800-468-6657).

Terminal Removal/Installation Tools

Just as important as having the right parts for the repair is having the right tools. The new Delphi.64 Connection System incorporates several new styles of tools all with color coded handles to simplify choosing the right tool for each terminal style.

IMPORTANT: Use of the proper terminal repair tools is critical to the correct installation of a new terminal and a secure tight fit.

IMPORTANT: Special promotional prices are now available on a Delphi .64 Service Kit, some J-35616 Terminal Test Probe Refills as well as a reduced price for the complete J-35616-C Test Probe Kit through August 1st, 2006. Contact SPX/Kent-Moore at 1-800-GM-TOOLS for specific details.

In an effort to further simplify the electrical repair process, additional information on terminal repair can now be found in SI for the 2007 model year and in some platforms of the 2006 and prior year models under the Master List of Electrical Components. Locating this information has changed for the 2007 model year in accordance with GM's new Global Table of Contents.

Enhanced Information and the GM Global Table of Contents

You may have already noticed that the SI table of contents has changed for the 2007 model year. Sections and Sub-Sections have been realigned to more logically group service items and repair procedures. Further, you can now find exact information on the required terminal part number and tools required to service them right in SI.

IMPORTANT: This information is present for the 2007 model year, and may be applicable to some models in the 2006 and prior years. For past models, the Master Electrical Component lists continues to be located under Body, Wiring Systems and then under Component Locator.

To locate terminal information for 2007 please do the following steps:

In SI, configure a 2007 vehicle and select NEXT.
SELECT: Service Manual/Bulletins
SELECT: Power and Signal Distribution
SELECT: Wiring Systems and Power Management
SELECT: Component Locator
SELECT: Master Electrical Component List

The master electrical component list contains hyperlinks to all of the connector end views in the selected vehicle. In addition to the usual connector drawing, you will see additional new information. The following is an example:

Example: Connector Part Information

You will now find information on the exact part number terminal required to perform a repair. This will include the service terminal pack part number, a full description, the location within the tray, the crimp style, and the required tool for the repair. The information is presented in a bulleted list as seen below.

IMPORTANT: The following is an example of the information found in the 2007 Chevrolet Tahoe Auxiliary Power Outlet Connector End View.

Auxiliary Power Outlet: (2007 Chevrolet Tahoe)

OEM: 12176446
Service: 15305923
Description: 3-Way F Metri-Pack 280 Series Flex Lock (GY)
Terminal/Tray: 12110844/4
Core/Insulation Crimp: C/A
Release Tool/Test Probe: 15315247/J-35616-4A (PU)

Utilizing this new information along with keeping your Electrical Terminal kit up to date should pay dividends in your service department with consistent and swift repairs.