Tyco/AMP Connectors (102-Way Inline)
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Tyco/AMP Connectors (102-Way Inline)
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Special Tools
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EL-38125-580
Terminal Release Tool Kit
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J-38125-11A
Terminal Release Tool
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J-38125-212
Terminal Release Tool
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J-38125-216
Terminal Release Tool
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J-38125-221
Terminal Release Tool
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J-38125-560
Terminal Release Tool
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J-38125-566
Terminal Release Tool
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For equivalent regional tools, refer to
Special Tools
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Terminal Removal Procedure
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View of a typical connector in the assembled position.
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1.
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Pull the locking lever to the 90 degree position from the connector body.
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2.
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With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal.
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3.
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Slide the male connector body out away from the guide plates.
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4.
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Note
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During assembly the terminal position assurance (TPA) will not fully seat if any terminal is not fully seated.
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Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body.
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5.
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Using terminal release tool J-38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.
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6.
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Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.
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7.
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Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.
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8.
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The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body.
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9.
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Move the locking lever 180 degrees from the connected position.
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10.
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With the locking lever in the 180 degree position the guide plates can be removed from the connector body.
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11.
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Note
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During assembly the TPA will not fully seat if any terminal is not fully seated.
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Using terminal release tool J-38125-11A or equivalent, remove the TPA from the connector body.
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12.
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Using terminal release tool J-38125-216, lift the terminal plate past the terminals and out of the connector body cavity.
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13.
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Terminal plate will bind slightly on each corner.
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14.
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Using terminal release tool J-38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.
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15.
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Using terminal release tool J-38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.
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16.
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Using terminal release tool J-38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body.
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17.
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Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner.
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18.
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With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever.
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19.
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Slide the male connector body back inward toward the guide plates.
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20.
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With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly.
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21.
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Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector.
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23.
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Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.
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