How To Replace Terminal

(with terminal retainer or secondary locking device) 

1. PREPARE THE SPECIAL TOOL

   HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left.

2. DISCONNECT CONNECTOR
   Fig 1: Identifying Special Tool Dimensions For Removing Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.
   1. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector.
   2. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer.
      NOTE: Do not remove the terminal retainer from connector body.
      Fig 2: Removing Secondary Locking Device And Terminal Retainer Using Special Tool

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. For Non-Waterproof Type Connector

         HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it.

         "Case 1"

         Raise the terminal retainer up to the temporary lock position.

         Fig 3: Identifying Full And Temporary Lock Positions Of Non-Waterproof Type Connector Terminal Retainer

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

         "Case 2"

         Open the secondary locking device.

         Fig 4: Identifying Secondary Locking Device

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         Fig 5: Opening Secondary Locking Device

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      2. For Waterproof Type Connector

      HINT: Terminal retainer color is different according to connector body.

      Example:

      Terminal Retainer  : Connector Body 

      Black or White : Gray

      Black or White : Dark Gray

      Gray or White : Black

      Fig 6: Pulling Terminal Retainer To Temporary Lock Position Using Special Tool

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      "Case 1"

      Type where terminal retainer is pulled up to the temporary lock position (Pull Type).

      Insert the special tool into the terminal retainer access hole ( Mark) and pull the terminal retainer up to the temporary lock position.

      HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it.

      Fig 7: Identifying Full And Temporary Lock Positions Of Waterproof Type Connector Terminal Retainer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      "Case 2"

      Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown.

      Fig 8: Inserting Special Tool Straight Into Access Hole Of Terminal Retainer

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Push the terminal retainer down to the temporary lock position.

      Fig 9: Pushing Terminal Retainer To Temporary Lock Position

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Release the locking lug from terminal and pull the terminal out from rear.
   Fig 10: Pulling Terminal Out From Rear Using Special Tool

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL TERMINAL TO CONNECTOR
   1. Insert the terminal.

      HINT:

      1. Make sure the terminal is positioned correctly.
      2. Insert the terminal until the locking lug locks firmly.
      3. Insert the terminal with terminal retainer in the temporary lock position.
      Fig 11: Identifying Connector Terminal Position

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Push the secondary locking device or terminal retainer in to the full lock position.
5. CONNECT CONNECTOR

Fig 12: Connecting Connector Terminal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002