Repairing Connector Terminals (Terminal Repair): Notes
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2011 GMC Yukon XL, 2011 GMC Yukon, 2011 Chevrolet Tahoe, 2011 Chevrolet Suburban, and 2011 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools
- J-38125-580 Terminal Repair Kit
- J-38125-6 Crimp Tool
- J-38125-7 Crimp Tool
- J-38125-8 Crimp Tool
- J-38125-64 Crimp Tool
- J-38125-101 Crimp Tool
- J-38125-641 Crimp Tool
- J-38125-642 Crimp Tool
- J-38125-643 Crimp Tool
For equivalent regional tools, refer to Special Tools .
Use the following repair procedures to repair each type of terminal:
- For push to seat terminals, refer to Delphi Connectors (Weather Pack) , Delphi Connectors (Pull To Seat) , Delphi Connectors (Push To Seat) , Delphi Connectors (12-Way) , Delphi Connectors (Micro.4) , Delphi Connectors (Steering Gear) , Delphi Connectors (Micro-Pack 100W) .
- For pull to seat terminals, refer to Delphi Connectors (Weather Pack) , Delphi Connectors (Pull To Seat) , Delphi Connectors (Push To Seat) , Delphi Connectors (12-Way) , Delphi Connectors (Micro.4) , Delphi Connectors (Steering Gear) , Delphi Connectors (Micro-Pack 100W) .
NOTE:
The first step for all terminal repairs is to find the connector end view in SI.
Cable Seal Terminals
- Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
- Remove the old seal.
- Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation.
- To minimize wire loss, remove only the insulation required.
- Using the connector end view, determine the correct crimp tool and crimp jaw.
- Align the seal with the end of the cable insulation.
- Position the stripped wire and seal in the terminal.
- Hand Crimp the core wings first.
- Hand Crimp the insulation wings around the seal and the cable.
- Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes.
Unsealed Terminals
- Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
- To minimize wire loss, remove only the insulation required.
- Position the stripped wire in the terminal.
- Hand Crimp the core wings first.
- Hand Crimp the insulation wings around the cable.
- Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes.