Wire Terminal Inspection and Removal

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Disconnect 

1. WARNING: Before beginning any service procedure in this article, refer to Health and Safety Precautions . Failure to follow this instruction may result in serious personal injury.
   NOTE: To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D or Terminal Probe Kit 29-011A must be used to connect test equipment or jumper wires to pins (terminals).
   • Male to female pin (terminal) fit is critical for correct connection and durability.
   • Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal separation force (a damaged pin or terminal will have very low separation force from the mating pin or terminal).
   • Correctly checking the separation force of small pins (terminals) may require removal of the connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or removal.
   • For more detail on the replacement of damaged connectors or pins (terminals) refer to the video below.
   multimedia:A supplement to the article is available.
2. NOTE: The connector hard-shell information, which is measured in millimeters is the distance from the front face of the connector to the engagement point on the terminal release tang. Mark the listed distance on the terminal removal tool prior to removing the terminal.
   NOTE: The dimensions of the connector hard-shell and the connector terminals release tang are listed above the corresponding graphics.
3. Audio Front Control Module (ACM), Body Control Module (BCM) and Instrument Panel Cluster (IPC) Electrical Connector 

   Callout	Connector
   1	External terminal release tang
   2	Electrical connector locking tab

   Courtesy of FORD MOTOR COMPANY

4. Audio Front Control Module (ACM), Front Controls Interface Module (FCIM), Gateway Module A (GWM), and Heating, Ventilation and Air Conditioning (HVAC) Control Module Electrical Connector 

   Callout	Connector
   1	Distance to release tang - 0.2953in (7.5mm) (inner terminal) - 0.4646in (11.8mm) (outer terminal)
   2	Terminal width size - 0.0244in (.62mm) (inner terminal) - 0.1102in (2.8mm) (outer terminal)

   Courtesy of FORD MOTOR COMPANY

5. Body Control Module (BCM) Electrical Connector 

   Callout	Connector
   1	Terminal width size - 0.1102in (2.8mm) (inner terminal) - 0.2480in (6.3mm) (outer terminal)
   2	Distance to release tang - 0.1260in (3.2mm) (inner terminal) - 0.1575in (4mm) (outer terminal)
   3	Terminal width size - 0.0591in (1.5mm)
   4	Distance to release tang - 0.3780in (9.6mm) (lower terminal)

   Courtesy of FORD MOTOR COMPANY

6. Body Control Module (BCM) Electrical Connector 

   Callout	Connector
   1	Terminal width size - 0.0591in (1.5mm) (inner terminal) - 0.1102in (2.8mm) (outer terminal)
   2	Distance to release tang - 0.3780in (9.6mm) (inner terminal)
   3	Distance to release tang - 0.1575in (4mm)
   4	Distance to release tang - 0.1575in (4mm)
   5	Terminal width size - 0.2480in (6.3mm)

   Courtesy of FORD MOTOR COMPANY

7. Body Harness In-line Electrical Connector 

   Callout	Connector
   1	Distance to release tang - 0.3346in (8.5mm)
   2	Terminal width size - 0.1102in (2.8mm)
   3	Terminal width size - 0.0591in (1.5mm)
   4	Distance to release tang - 0.3858in (9.8mm) (inner)

   Courtesy of FORD MOTOR COMPANY

8. Body Harness In-line Electrical Connector 

   Callout	Connector
   1	Distance to release tang - 0.3543in (9mm)
   2	Terminal width size - 0.0591in (1.5mm) (inner terminal) - 0.1102in (2.8mm) (outer terminal)
   3	Terminal width size - 0.2480in (6.3mm)
   4	Distance to release tang - 0.3543in (9mm)

   Courtesy of FORD MOTOR COMPANY

9. Body Harness In-line and Seat Harness Electrical Connector 

   Callout	Connector
   1	Distance to release tang - 0.4331in (11mm)
   2	Terminal width size - 0.0591in (1.5mm)
   3	Terminal width size - 0.0591in (1.5mm)
   4	Distance to release tang - 0.4331in (11mm)

   Courtesy of FORD MOTOR COMPANY

10. Body Harness In-line and Seat Module Electrical Connector 

    Callout	Connector
    1	Terminal width size - 0.0591in (1.5mm)
    2	Distance to release tang - 0.3937in (10mm)

Courtesy of FORD MOTOR COMPANY