Downloaded from www.Manualslib.com manuals search engine CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component
(3) Remove the connector locking wedge, if
required (Fig. 16)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 17) (Fig. 18).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/compo-
nent.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 19).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra lengthfor soldered connections. Check that the overall
length is the same as the original (Fig. 19).
(7) Remove 1 inch of insulation from each wire.
Fig. 16 Connector Locking Wedge
Fig. 17 Terminal Removal
Fig. 18 Terminal Removal Using Special Tool
Fig. 19 Stagger Cutting Wires
PL8W - 01 GENERAL INFORMATION 8W - 01 - 9
SERVICE PROCEDURES (Continued)
