Terminal Replacement

  • Cut off the old terminal between the core crimp and the insulation crimp to minimize wire loss.  Also cut off any damaged portions of the wire to be used.

  • Install a wire seal if applicable.

  • Strip approximately 1/4" of insulation off of the wire.

  • Obtain the correct replacement terminal.

  • Insert the exposed wire strands into the core wing area of the terminal.  

  • Crimp the terminal core wings with a "W" style crimping tool.  

  • Crimp the insulation wings of the terminal onto the wire insulation

  • Tug on the wire to insure it does not come out of the terminal.  Crimping too hard can cut the wire strands and cause excessive resistance in the wire connection.

  • Using a soldering iron, solder the connection to insure a good electrical connection.

  • Test the circuit for continuity.
Citation: jfrank. (2008, February 12). Terminal Replacement. Retrieved November 22, 2009, from WSU Web site: http://ocw.weber.edu/automotive-technology/ausv-1320-automotive-electronics/9-wiring-repair/terminal-replacement.
Copyright 2008, by the Contributing Authors. This work is licensed under a Creative Commons License. Creative Commons License