Delphi Connectors (Weather Pack)

Wiring Systems and Power Management | Diagnostic Information and Procedures | Document ID: 5207166 Special Tools EL-38125-550 Terminal Release Tool Kit EL-38125-580 Terminal Release Tool Kit J-38125-10A Terminal Release Tool For equivalent regional tools, refer to Special Tools. Terminal Removal Procedure The following is the proper procedure for the repair of Weather Pack® Connectors.

Delphi Connectors (Weather Pack) — figure 1

1. Separate the connector halves (1).
2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1).
3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position.

Delphi Connectors (Weather Pack) — figure 2

4. Insert the Weather Pack® terminal removal tool J-38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2).

Note

Never use force to remove a terminal from a connector.

6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals.
7. Reform the lock tang (2) and reset terminal in connector body.
8. Close secondary locks and join connector halves.
9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.
11. Repair the terminal by following the Repairing Connector Terminals procedure.
12. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.