Repairing Connector Terminals (Terminal Repair): Notes

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) , or Delphi Connectors (Push to Seat) , or Delphi Connectors (Pull to Seat) , or Delphi Connectors (Micro Pack 100W) , or Delphi Connectors (Micro.64) , or Delphi Connectors (12-Way) , or Delphi Connectors (Steering Gear) .
• For pull to seat terminals, refer to Delphi Connectors (Weather Pack) , or Delphi Connectors (Push to Seat) , or Delphi Connectors (Pull to Seat) , or Delphi Connectors (Micro Pack 100W) , or Delphi Connectors (Micro.64) , or Delphi Connectors (12-Way) , or Delphi Connectors (Steering Gear) .

Cable Seal Terminals

1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
2. Remove the old seal.
3. 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.
4. To minimize wire loss, remove only the insulation required.
5. Using the connector end view, determine the correct crimp tool and crimp jaw.
6. Align the seal with the end of the cable insulation.
7. Position the stripped wire and seal in the terminal.
8. Hand Crimp the core wings first.
9. Hand Crimp the insulation wings around the seal and the cable.

Unsealed Terminals

1. Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
2. To minimize wire loss, remove only the insulation required.
3. Position the stripped wire in the terminal.
4. Hand Crimp the core wings first.
5. Hand Crimp the insulation wings around the cable.