J 38125 620H

TABLE OF CONTENTS
ITEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE NUMBER
GENERAL INSTRUCTIONS
Definition Of Terms And Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Terminal Removal Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Terminal Replacement Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Crimp Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Ultratorch Usage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Splice Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Splice Crimp Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Kit Contents, Re-Order Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18
Tray Labels And Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-47
J-38125 Tool Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-50
TERMINALS & CONNECTORS

AFL/EPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-56
DELPHI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-75
EMPIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
FCI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
JST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-79
KOSTAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
MOLEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-82
SUMITOMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-89
TYCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100
YAZAKI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101-111
CRIMP MATRIX
AFL TRAY #21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DELPHI TRAY #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DELPHI TRAY #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
DELPHI TRAY #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DELPHI TRAY #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
DELPHI TRAY #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DELPHI TRAY #8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DELPHI TRAY #18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
DELPHI TRAY #19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
DELPHI TRAY #20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
DELPHI TRAY #23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DELPHI TRAY #24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
LEAR TRAY #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
LEAR TRAY #16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
LEAR TRAY #17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
LEAR TRAY #25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
LEAR TRAY #28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
SUMITOMO TRAY #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
SUMITOMO TRAY #22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
SUMITOMO TRAY #26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
YAZAKI TRAY #9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
YAZAKI TRAY #10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
YAZAKI TRAY #11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
YAZAKI TRAY #12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
YAZAKI TRAY #13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
YAZAKI TRAY #14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
YAZAKI TRAY #15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
YAZAKI TRAY #27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
DEFINITION OF TERMS
Cable
Another term for a bulk length of wire.
Connector
The molded plastic part which houses one or

more terminals.
Connector Position Assurance
A lock designed to retain connectors when mated.
Core
Conductive portion of a wire, covered with insulation

of various types - usually PVC or polyethylene.
Crimp & Seal Splice Sleeve
A crimp only splice with an integral heat shrink shield

used to make a sealed one to one splice.
Lead
Another term for a cut length of wire.
Pick
Removal tool for terminal, TPA, CPA or opening of

secondary locks.
Pigtail
Terminated wires housed in a connector intended to be

spliced into a harness when total harness replacement
is not required.
Secondary Lock
Provides terminal retention in addition to lock tang,

usually molded as part of the connector.
Terminal
Formed metal attached to the end of the wire that

provides electrical connection.
Terminal Lock Tangs
Flexible portion of the terminal that locks terminal into

connector cavity.
Terminal Position Assurance
A loose piece component that snaps on to a connector.

It is designed to keep the terminal from backing out of
the connector.
Terminal Wings
Portion of terminal that is used for attachment to wire.

Typical terminal has core wings, attached to the
conductive core of the wire and insulation wings,
attached to the outside of the wire for strain relief.
ABBREVIATIONS
ACT
Advanced Connection Technology, the next generation metri pack having lower
terminal to terminal engage force
CPA
Connector Position Assurance lock
MIC/P
Micro Pack, a family of sealed and unsealed connection systems used primarily in low
current (signal level) applications
M/P
Metri Pack, a family of sealed and unsealed connection systems of various sizes and
current carrying capacities
P2S
Pull to Seat, a connection system where the terminal on a wire is actually inserted
into the mating end of the connector, wire first, so that an unseated terminal does not
push out the back of the connector and cause an electrical open circuit.
TPA
Terminal Position Assurance lock
W/P
Weather Pack, a family of sealed connection systems utilizing a pin and

sleeve configuration
Acknowledgement: Technical Information provided courtesy of John Roberts

General Motors Service Engineering - Electrical Group, November 2007
TERMINAL REMOVAL INSTRUCTIONS

Terminal retention within the connector generally takes two forms:
1. A flexible primary lock, either part of the terminal or part of the connector
2. A hinged or loose piece secondary lock. To remove a terminal, both must
be disengaged or removed.
First, locate and remove the secondary lock.
1. Most are located in the rear (non-mating end) of the connector. These can generally be
removed using a small screwdriver.
2. The new GT series and 100W micropack styles have the secondary lock on the front
(mating) end of the connector. 100W can be removed with a screwdriver, the GT requires
the use of pick #15313892. It will allow you to hook the secondary lock and gently lift
it out of place.
Now remove the terminal by disengaging the primary lock.
1. Determine the terminal part number or family, then get the appropriate removal tool using
the crimp matrix section of this book.
2. Locate the area of the front of the connector where the removal tool is to be inserted. It will
NEVER enter the portion of the terminal where the mating terminal would be located.
Inserting the removal tool into this mating area will RUIN the terminal.
3. Position the terminal by using the attached wire. For push to seat, slide the terminal
forward. For pull to seat, slide it rearward. This allows the lock tang to disengage from
the lock shoulder.
4. Terminal locks which are flexible members in the connector are ACT, GT and 100W
micropacks. All others have the lock tang as part of the terminal. Using appropriate tool
from the matrix, flex the plastic lock member, then gently remove the terminal by pushing
or pulling on the wire.
5. For families with the lock tang on the terminal, gently insert the removal tool and disengage
the lock while holding the terminal in the position from step #3. The terminal can be removed
by pushing or pulling on the wire.
STANDARD TERMINAL REPLACEMENT

1
CUT OFF TERMINAL BETWEEN CORE AND
INSULATION CRIMP.
(MINIMIZE WIRE LENGTH LOSS)
STRIP INSULATION APPROPRIATE TO THE

TERMINAL BEING CRIMPED.
USE CAUTION WHEN STRIPPING INSULATION
BEING CAREFUL NOT TO CUT THROUGH THE
WIRE STRANDS.
POSITION WIRE IN TERMINAL AS SHOWN.

CAUTION MUST BE USED NOT TO POSITION
STRIP TOO FAR FORWARD. IT MAY INTERFERE
WITH MATING PORTION OF TERMINAL.
HAND CRIMP CORE WINGS FIRST, THEN

INSULATION WINGS USING ONE OF THE
APPROVED CRIMPING TOOLS. USE CRIMP
MATRIX SECTION TO DETERMINE CORRECT
TOOL COMBINATION.
5
DO NOT SOLDER SMALL 100 AND .64
TERMINALS AS SOLDERING WILL DESTROY
THE TERMINAL. USING THE PROPER CRIMP
TOOL WILL PROVIDE THE APPROVED REPAIR.
TERMINAL REPLACEMENT SEALED

WEATHER PACK AND METRI-PACK
1
CUT OFF TERMINAL BETWEEN CORE AND

INSULATION CRIMP.
REMOVE SEAL
APPLY CORRECT SEAL PER GAUGE SIZE OF

WIRE. SLIDE BACK TO ENABLE REMOVAL OF
INSULATION. STRIP INSULATION APPROPRIATE
TO THE TERMINAL BEING CRIMPED. ALIGN
SEAL WITH CABLE INSULATION.
WIRE STRANDS.
POSITION STRIP AND SEAL IN TERMINAL AS

SHOWN. CAUTION MUST BE USED NOT TO
POSITION STRIP TOO FAR FORWARD. IT
MAY INTERFERE WITH MATING PORTION
OF TERMINAL.
HAND CRIMP CORE WINGS FIRST, THEN

INSULATION WINGS USING ONE OF THE
APPROVED CRIMPING TOOLS. USE CRIMP
MATRIX ON PAGES 45-67 TO DETERMINE
CORRECT TOOL COMBINATION.
5
DO NOT SOLDER TERMINALS AS SOLDERING
WILL DESTROY THE TERMINAL. USING THE
PROPER CRIMP TOOL WILL PROVIDE THE
APPROVED REPAIR.
TERMINAL CRIMP TOOL
J-38125-6
J-38125-7
J-38125-8
J-38125-64
J-38125-101
J-38125-641
J-38125-642
J-38125-643
J-38125-101 is used for Delphi 100W round terminals which use crimp
jaw W in the crimp matrix.
J-38125-64 is used for Delphi .64 round terminals which use crimp jaw
M in the crimp matrix..
Both J-38125-641 and J-38125-642 are used for .64 square terminals
with or without cable seals.
TERMINAL CRIMP TOOL

1. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY OPENS.
2. DETERMINE THE CORRECT HOLDER PER CRIMP MATRIX SECTION.
3. CORE WINGS SHOULD BE CRIMPED FIRST. LAY THE BACK OF THE TERMINAL
CORE WINGS ON APPROPRIATE ANVIL. BE SURE THE CORE WINGS ARE POINTING
TOWARDS THE FORMING JAWS.
4. GENTLY APPLY PRESSURE TO HANDLES UNTIL CRIMPERS SLIGHTLY SECURE THE
TERMINAL CORE WINGS.
5. INSERT STRIPPED CABLE THROUGH CORE CRIMP WINGS OF TERMINAL AND
POSITION PROPERLY.
6. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY RELEASES.

7. REPEAT STEPS 2 AND 3 FOR INSULATION CRIMP.
8. LOOK AT TERMINAL FOR DAMAGE PRIOR TO APPLYING SOLDER. IF TERMINAL
APPEARS BENT AFTER CRIMPING, IT SHOULD BE GENTLY STRAIGHTENED BY HAND.
SPLICE CRIMP TOOL

J-38125-8 / P/N (F-G) 12085115
GREEN FILL
SALMON FILL
BLUE FILL
YELLOW FILL
1. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY OPENS.

2. DETERMINE THE CORRECT SPLICE HOLDER (NEST) PER SPLICE CRIMP MATRIX
ON PAGE 20.
3. GENTLY APPLY PRESSURE TO HANDLES UNTIL CRIMPERS SLIGHTLY SECURE THE
SPLICE SLEEVE BARREL. NOTE: MUST BE CRIMPED IN TWO STAGES - LEFT AND RIGHT.
4. INSERT STRIPPED CABLE THROUGH SLEEVE BARREL UNTIL WIRE HITS THE
STOP POSITION.
5. COMPRESS THE HANDLES UNTIL RATCHET AUTOMATICALLY RELEASES.
6. REPEAT STEPS 3, 4 AND 5.

7. GENTLY TUG ON THE WIRES TO MAKE SURE THEY ARE SECURE BEFORE APPLYING
HEAT TO SLEEVE.
8. APPLY HEAT FROM CENTER TO OUTSIDE OF SLEEVE WHILE ROTATING THE SLEEVE,
TO PREVENT OVER HEATING THE SPLICE SLEEVE OR WIRE INSULATION.
ULTRATORCH
J-38125-5 / P/N 12085116
PLEASE READ OPERATING INSTRUCTIONS INCLUDED WITH THE ULTRATORCH. THE
FOLLOWING ADDITIONAL INSTRUCTIONS WILL HELP IN MAKING QUALITY APPLICATIONS.
1. USE CARE IN REFILLING TORCH.
2. MAXIMUM SETTING FOR GAS CONTROL LEVER WHEN APPLYING HEAT TO SPLICE
SLEEVES OR TERMINAL APPLICATIONS IS 3 1/2.
3. USE CARE IN CONFINED AREAS SUCH AS ENGINE COMPARTMENT OR NEXT
TO ANYTHING THAT CAN EASILY MELT (CARPET, PLASTIC COMPONENTS, ETC.)
ADJUST GAS CONTROL LEVER TO APPROXIMATELY 2 TO 2 1/2 SETTING WHEN
IN CONFINED AREAS.
4. WHEN USING THE SOLDERING TIP ATTACHMENT, ALLOW APPROXIMATELY 1 MINUTE
FOR TOOL TO HEAT UP. THIS WILL ALLOW THE SOLDER TO FLOW PROPERLY ON THE
TERMINAL CORE CRIMP.
10
VISUAL STANDARDS
TERMINAL APPLICATION
TERMINAL WITH SEAL APPLICATION
SPLICE APPLICATION
CRIMP AND SEAL APPLICATION
11
VISUAL STANDARDS
SOLDER APPLICATION
SPLICE CLIP
GLUED HEAT SHRINK APPLICATION
12
SPLICE CLIP
P/N 821240, 05297428, 01839906
CUT OFF CLIP. STRIP INSULATION (1/2 LENGTH).

WIRE STRANDS.
PREFERRED: LOCATE NEW SPLICE 40 MM

(1.5) MINIMUM FROM AN OUTLET OR ANOTHER
SPLICE. DETERMINE PROPER SPLICE CLIP
FOR GAUGE SIZE OF WIRES. POSITION CLIP
ON STRIPS.
3
SLIDE HEAT SHRINK TUBING OVER WIRE
TO BE SPLICED. HAND CRIMP TO SECURELY
CLOSE THE ENTIRE CLIP USING CRIMPERS
OR PLIERS. (SEE CRIMP MATRIX)
4
SOLDER SPLICE CLIP
5
COVER ENTIRE SPLICE WITH HEAT SHRINK
TUBING. TUBING MUST EXTEND ONTO THE
INSULATION ON BOTH SIDES OF SPLICE.
13
DURASEAL CRIMP SPLICE SLEEVE

THERE ARE NOW FOUR DURASEAL SOLDERLESS SPLICE SLEEVES AVAILABLE FOR
WIRE REPAIR. IN 2004 A GREEN SLEEVE WAS ADDED TO ACCOMMODATE 24-22
AWG WIRE SIZES.
Yellow 12-10 AWH PN 12089191
Blue 16-14 AWG PN 12089190
Salmon 20-18 AWG PN 12089189
Green 24-22 AWG PN 88988379
14
CRIMP AND SEAL SPLICE SLEEVE

P/N 12089189, 12089190, 12089191, 88988379
1
CUT OFF CLIP IF APPLICABLE. STRIP

INSULATION. 3/16 LENGTH FOR 10
THRU 22 GA.
WIRE STRANDS.
PREFERRED: LOCATE NEW SPLICE 40 MM

(1.5) MINIMUM FROM AN OUTLET OR ANOTHER
SPLICE. DETERMINE PROPER SLEEVE FOR
GAUGE OF WIRE. POSITION STRIPPED ENDS OF
WIRE INTO SLEEVE UNTIL WIRE HITS THE STOP.
HAND CRIMP USING CRIMPING TOOL J-38125-8.

GENTLY TUG ON WIRE TO MAKE SURE THEY
ARE SECURE BEFORE APPLYING HEAT TO SLEEVE.
APPLY HEAT USING ULTRATORCH OR OTHER

DEVICE HEATING TO 175C. REFER TO PG. 12.
CAUTION: DO NOT USE MATCH OR OPEN
FLAME TO APPLY HEAT TO SEAL
IN SOME EXTREME HIGH TEMPERATURE

APPLICATIONS (IE UNDER HOOD, NEAR
EXHAUST SYSTEMS, ETC) HEAT SHRINK TUBE
(J-38125-TUBE) MUST BE PLACED OVER THE
COMPLETED CRIMP AND SEAL SPLICE TO
PRESERVE THE INTEGRITY OF SPLICE SEAL.
15
SEALED SPLICE CRIMP MATRIX

SEALED SPLICE CRIMP MATRIX (one to one splice only)
Part Number
Color
0.22
0.35
88988379
Green
12089189
Salmon
12089190
Blue
12089191
Yellow
0.5
0.8
The unsealed splice clips are designed to be crimped and soldered. Each clip may contain only
a certain combination of wires, expressed in area. Use the table below to determine which clip
works with your combination.
Wire size
.022
0.35
0.5
0.8
Area - sq mm
0.051
0.308
0.549
0.805
1.177
1.947
3.019
4.756
Splice clip P/N
Recommended area in crimp
821240
2.80 - 5.50 mm2
1839906
5.50 - 8.90 mm2
5297428
2.16 - 3.29 mm2
ENGLISH/METRIC GAUGE CONVERSION TABLE
METRIC SIZE (SQ MM)

0.22
0.35
0.5
0.75
0.8
1
1.50
2
2.50
3
5
8
13
19
SAE SIZE (GAUGE)

24
22
20
N/A
18
16
N/A
14
N/A
12
10
8
6
4
16
J-38125-H ESSENTIAL TOOL KIT

Description
Terminal tray #1 (Delphi)
Terminal tray #6 (Sumitomo)
Terminal tray #7 (Lear)
Terminal tray #9 (Yazaki)
Terminal tray #21 (AFL)
Release Tool - Weather Pack - Yellow
Release Tool - Standard Large - Blue
Release Tool - Standard Small - Green
Release Tool - Micro Pack - Red
Release Tool - Micro .64 - Red
Release Tool - Micro .64 male - Tan
Release Tool - Tyco .64 MQS - Green
Release Tool - Deutch 250 - Lt. Blue
Release Tool - Deutch 150 - Orange
Release Tool - Kostal - Round 150 - Green
Release Tool - Delphi Flex Beam - Yellow
Release Tool - Micro Pack 100W - Gray
Part No.
12085267
12085266
12188910
12188911
12188912
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
12014012-1
12094430
12094429
12031876-1
15381651-2
15389891
N/A
0411-310-1605
0411-337-1205
N/A
13558833-1
12122523
17
J-Number
J-38125-TRAY1
J-38125-TRAY2
J-38125-TRAY3
J-38125-TRAY4
J-38125-TRAY5
J-38125-TRAY6
J-38125-TRAY7
J-38125-TRAY8
J-38125-TRAY9
J-38125-TRAY10
J-38125-TRAY11
J-38125-TRAY12
J-38125-TRAY13
J-38125-TRAY14
J-38125-TRAY15
J-38125-TRAY16
J-38125-TRAY17
J-38125-TRAY18
J-38125-TRAY19
J-38125-TRAY20
J-38125-TRAY21
J-38125-TRAY22
J-38125-TRAY23
J-38125-TRAY24
J-38125-TRAY25
J-38125-TRAY26
J-38125-TRAY27
J-38125-TRAY28
J-38125-10A
J-38125-11A
J-38125-12A
J-38125-13A
J-38125-21
J-38125-22
J-38125-24
J-38125-26
J-38125-27
J-38125-28
J-38125-29
J-38125-33
J-38125-H ESSENTIAL TOOL KIT

Release Tool - Tyco - Lt. Blue
Release Tool - JAE .64 - Blue
Release Tool - Tyco 280 Male JPT - Black
Release Tool - Molex .64 - Gray
Release Tool - Tyco 100 - Black
Release Tool - Yazaki Kaizen .64 - Purple
Release Tool - Round Hook TPA Removal Tool - Green
Release Tool - Molex 150 - Black
Release Tool - Tyco 480 - Orange
Release Tool - Tyco 100 - Lt. Blue
Release Tool - Tyco 950 - Green
Release Tool - Tyco 250 female - Brown
Release Tool - Round Hook - TPA Removal Tool - Blue
Release Tool - Micro Pack 280, 480 - Black
Release Tool - Molex Pin 280 - White
Release Tool - Tyco 280 JPT/Mini-Timer - Yellow
Release Tool - Tyco 150 Mini-Timer - White
Release Tool - M/P 800 Maxi Fuse - Blue
Pin Vise
Release Tool - Bosch .64 BMK - White
Release Tool - Bosch 280 BSK - White
Crimper - 1 thru 5
Crimper - A thru E
Crimper - F&G - Sealed Splice
Crimper - M
Crimper - W
Crimper - 6 thru 8
Crimper - H thru K
Crimper - N 9 & P
Ultra Torch
3.3MM Solder Tip
Heat Tip
Heat Shrink Attachment
Connector Parts Tray
Cabinet (Holds 5 trays) 7 each
Tool Tray
Reference Guide
Crimp Tool Box
SIR Tray
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
15313892
15315247
12152110
12093647
12122378
12150860
12180559-1
15314260
N/A
12085270
12085271
12085115
15397700
12125080
N/A
N/A
N/A
12085116
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
CONT.
J-38125-36
J-38125-211
J-38125-212
J-38125-213
J-38125-214
J-38125-215A
J-38125-216
J-38125-217
J-38125-218
J-38125-220
J-38125-221
J-38125-222
J-38125-552
J-38125-553
J-38125-554
J-38125-556
J-38125-557
J-38125-558
J-38125-559
J-38125-560
J-38125-561
J-38125-6
J-38125-7
J-38125-8
J-38125-64
J-38125-101
J-38125-641
J-38125-642
J-38125-643
J-38125-5
J-38125-18
J-38125-19
J-38125-20
J38125-605
J-38125-610
J-38125-615
J-38125-620H
J-38126-625
J-38125-SIR
All components listed above are available from Kent-Moore. Please call (800) 345-2233 for orders.
18
YOUR TRAY LABEL SHOULD MATCH THE LABEL

SHOWN ABOVE. IF NOT, AN UPDATE IS REQUIRED.
TRAY #1 DELPHI AUTOMOTIVE
19
20
17
523277 REV B
Tray 2
12129493
12020120
15326030
12077411
12033820
12047581
18
10
12048159
12015870
12034046
12048451
12020126
20
12
12066132
12048074
12034047
21
13
WHITE
22
12048441
12103881
BLUE
14
12124304
12048087
12045773
12020116

19
11
12066214
23
15
DEC 2007
TAN
16
24
12041351
12089340
12084595

21
22
17
523279 REV C
Tray 4
12110853
15305000
12177150
15324989
12110652
12015858
18
10
1241818-1
12110657
12015860
12160643
12110842
20
12
12160644
12110844
13525969
21
13
15359541
12110845
12077413

19
11
12191316
22
14
WHITE
15366021
15336703
12084586
23
15
DEC. 2007
16
24
15410621
12110847
13525970

23
24
Tray 6
17
8100-2493
7165-0815
7165-0347
528440 REV C
8100-1710
7165-0797
7160-9465
18
10
19
11
8100-0544
8100-0461
7165-0349
20
12
21
8230-4040
13
8100-0468
7165-0356
22
8230-4282
14
8100-0594
7165-0395

8100-2512
REPLACED
WITH
7116-4025
TRAY 11
8100-0460
7165-0348
23
8240-4140
15
8100-1466
7165-0547
DEC 2007
24
8240-4422
16
8100-1467
7165-0796
TRAY #6 SUMITOMO
25
17
522370 REV C
Tray 7
2-968037-4
184030-1
1123343-2
10
18
771016-HK200
184095-1
1719532-5
11
12
20
771816-HK200
184140-1
154718-3
173716-1
184141-1
171631-2
21
13
280756-4
22
14
1-968857-3
171661-5

19
771416-HK200
184139-1
963716-2
282224-1
23
15
1-968859-3
172748-1
DEC 2007
24
282225-1
16
2-927835-2
173630-7
TRAY #7 LEAR

26

TRAY #9 YAZAKI
27

TRAY #10 YAZAKI
28

TRAY #11 YAZAKI
29
30
17
107216 REV C
Tray 12
22124472200
7116-1558-08
7116-1343
10
18
10800444522
7116-2095
7114-1680-02
19
11
12
20
7116-2640-02
7116-2092
7114-1467-02
21
REPLACED
WITH
7116-4641-02
THIS TRAY
7116-2641
13
7114-1471
7114-1468-02
22
7116-2641-02
14
7114-1472
7116-1767-08

REPLACED
WITH
7116-4640-02
THIS TRAY
7116-2640
7116-2090
7116-1680-02
23
REPLACED
WITH
7116-4642-02
THIS TRAY
7116-2642
15
7116-1471
7116-1768-08
DEC 2007
24
7116-2642-02
16
7116-1472
7116-1557-08
TRAY #12 YAZAKI
31
Tray 13
7157-3852
17
7158-3007-10
7157-3891
18
7157-3920-40
107217 REV C
10
7158-3008-80
7157-3950-80
20
7158-3031-90
12
7158-3082-90
7157-3977-50
21
7157-3646
13
7158-3083
7157-7811-80
22
7157-3648
14
7158-3111-60
7157-7812

19
7158-3030-50
11
7158-3081-50
7157-3976-60
23
7158-3032-60
15
7158-3112-70
7157-7935
DEC 2007
24
7158-3080-60
16
7158-3113-40
7158-3006-90
TRAY #13 YAZAKI
32
17
522363 REV D
Tray 14
7116-6046
7114-6046
7114-1257-02
7116-6047
7114-6047
7114-3250
18
10
19
12
20
7114-4721-02
7116-4036
7114-4036
21
7116-4035
13
7116-4037
7114-4037
22
7116-4721-02
14
7116-4060-02
7114-4060-02

7114-1050
11
7116-1257-02
7114-3251
16
7116-4720-02
7114-4720-02
23
DEC 2007
24
SAIT-A03T-M064 SAITS-A03T-M064
15
7116-4231-08
7114-4231-08
TRAY #14 YAZAKI

TRAY #15 YAZAKI
33

TRAY #16 LEAR
34
35
17
522366 REV D
Tray 17
344070-1
1241406-1
968072-2
347707-1
1326029-1
968074-2
18
10
19
11
770678-1
1326030-6
968121-2
20
12
776491-1
21
13
1326030-8
968122-2
967652-1
22
14
1456350-1
1241374-1

62336-1
1326029-8
968075-2
23
1928498014
15
1488220-1
1241388-1
DEC 2007
24
1928498016
16
173681-2
1241390-1
TRAY #17 LEAR

36
37
17
522368 REV D
Tray 19
15305100
12176636
12103514
REPLACED
WITH
7116-1181
TRAY 11
15305180
12177007
12110127
18
10
19
11
15326267
15304702
12129484
20
12
15326269
15304713
REPLACED
WITH
8240-4892
TRAY 22
12129960
21
13
22
15326592
14
15304719
12146448

15324340
12191812
12124313
23
1928498135
15
15304720
12147300
DEC 2007
24
REPLACED
WITH
1928498135
THIS TRAY
1928498136
16
15304731
12147303

38

TRAY #21 AFL
39

TRAY #22 SUMITOMO
40

41

42
43
17
532541 REV B
Tray 25
771316-HK200
4-964274-1
963720-3
10
18
771716-HK200
2-964280-1
104479-9
11
927837-1
20
12
4-965999-1
1411553-1
927837-7
770520-1
21
13
1411560-2
962928-1
770903-1
22
14
1411590-1

19
772216-HK200
2-964284-1
1241380-2
964328-1
770904-1
144969-1
23
15
DEC 2007
24
967011-1
16
771116-HK200
170258-1
TRAY #25 LEAR

TRAY #26 SUMITOMO
44
45
17
532545 REV D
Tray 27
SAIT-A03GF-M064
7157-8767
18
10
7158-3504-80
7158-3503-50
2 2124 472970
1 0800 444523
20
7158-3116-50
12
7114-4618-02
7116-1531
175091-1
21
13
7116-1050
7116-3252
22
2 2140 492060
14
7116-2033-02
7157-3580-60

19
7158-3114-90
11
7158-3505-40
7116-1261
23
1062-12-0166
15
7116-2951-02
7157-3791-60
DEC 2007
24
1062-16-0622
16
7116-2952-02
7158-3374-90
TRAY #27 YAZAKI

TRAY #28 LEAR
46
ADDITIONAL TRAYS
Connector Parts Tray
CONTENTS:
QTY/PKG PART #
5
5
5
5
5
5
5
5
5
5
5
5
12
DESCRIPTION
15356665
15356810
15357143
15357161
15359061
15359196
15359537
15393131
15404970
15404997
15433830
15465038
J-38125-TUBE
TPA 50 Way Connector

TPA 8 Way Connector
Shrink Tube
SIR Tray
CONTENTS:
QTY/PKG PART #
1
5
5
4
2
3
3
5
5
5
4
5
4
DESCRIPTION
526438
12020833
12052834
12085510
12085514
12102725
12102726
12110299
15393422
15404224
15435886
54590003
1393365-2
Yellow Tape
SIR CPA
SIR CPA
Terminated Lead
SIR Pigtail
Terminated Lead
Terminated Lead
SIR CPA
SIR CPA
SIR CPA
Terminated Lead
SIR CPA
Terminated Lead
Tool Tray
J-38125-615
Used to store release tools and Ultra Torch.
47
J-38125-H TOOLS
RELEASE TOOL
Weather Pack - Yellow
Part #: 12014012-1
Order #: J-38125-10A
RELEASE TOOL
Deutch 250 - Lt. Blue
Part #: 0411-310-1605
Order #: J-38125-26
RELEASE TOOL
Standard Large - Blue
Part #: 12094430
Order #: J-38125-11A
RELEASE TOOL
Deutch 150 - Orange
Part #: N/A
Order #: J-38125-27
RELEASE TOOL
Standard Small - Green
Part #: 12094429
Order #: J-38125-12A
RELEASE TOOL
Kostal - Round 150 - Green
Part #: 44411
Order #: J-38125-28
RELEASE TOOL
Micro Pack - Red
Part #: 12031876-1
Order #: J-38125-13A
RELEASE TOOL
Delphi - Flex Beam - Yellow
Part #: 13558833-1
Order #: J-38125-29
RELEASE TOOL
Micro .64 - Red
Part #: 15381651-2
Order #: J-38125-21
RELEASE TOOL
Micro Pack 100W - Gray
Part #: 12122523
Order #: J-38125-33
RELEASE TOOL
Micro .64 Male - Tan
Part #: N/A
Order #: J-38125-22
RELEASE TOOL
Tyco - Light Blue
Part #: N/A
Order #: J-38125-36
RELEASE TOOL
Tyco .64 MQS - Green
Part #: N/A
Order #: J-38125-24
RELEASE TOOL
JAE .64 - Blue
Part #: N/A
Order #: J-38125-211
48
J-38125-H TOOLS
CONT.
RELEASE TOOL
Tyco 280 Male JPT - Black
Part #: N/A
Order #: J-38125-212
RELEASE TOOL
Tyco 100 - Lt. Blue
Part #: N/A
Order #: J-38125-220
RELEASE TOOL
Molex .64 - Gray
Part #: N/A
Order #: J-38125-213
RELEASE TOOL
Tyco 950 - Green
Part #: N/A
Order #: J-38125-221
RELEASE TOOL
Tyco 100 - Black
Part #: N/A
Order #: J-38125-214
RELEASE TOOL
Tyco 250 Female - Brown
Part #: N/A
Order #: J-38125-222
RELEASE TOOL
Yazaki Kaizen .64 - Purple
Part #: N/A
Order #: J-38125-215A
RELEASE TOOL
Round Hook TPA Removal Tool - Blue
Part #: 15313892
Order #: J-38125-552
RELEASE TOOL
Round Hook TPA
Removal Tool - Brown
Part #: N/A
Order #: J-38125-216
RELEASE TOOL
Micro Pack 280, 480 Black
Part #: 15315247
Order #: J-38125-553
RELEASE TOOL
Molex 150 - Black
Part #: N/A
Order #: J-38125-217
RELEASE TOOL
Molex Pin 280 - White
Part #: 12152110
Order #: J-38125-554
RELEASE TOOL
Tyco 480 - Orange
Part #: N/A
Order #: J-38125-218
RELEASE TOOL
Tyco 280
JPT/Mini-Timer - Yellow
Part #: 12093647
Order #: J-38125-556
49
J-38125-H TOOLS
RELEASE TOOL
Tyco 150
Mini-Timer - White
Part #: 12122378
Order #: J-38125-557
CONT.
CRIMPER - M
Part #: 15397700
J-Number: J-38125-64
CRIMPER- W
Part #: 12125080
J-Number: J-38125-101
RELEASE TOOL
M/P 800 Maxi Fuse - Blue
Part #: 12150860
Order #: J-38125-558
CRIMPER - H, J, K
Part #: N/A
Order #: J-38125-641
Pin Vise
Part #: 12180559-1
Order #: J-38125-559
CRIMPER - 6, 7, 8
Part #: N/A
Order #: J-38125-642
RELEASE TOOL
Bosch .64 BMK - White
Part #: 15314260
Order #: J-38125-560
CRIMPER - N, 9, P
Part #: N/A
Order #: J-38125-643
RELEASE TOOL
Bosch 280 BSK - White
Part #: N/A
Order #: J-38125-561
Ultra Torch
Part #: 12085116
Order #: J-38125-5
INCLUDES:
3.3MM Solder Tip
Heat Tip
Heat Shrink Attachment
CRIMPER - 1 thru 5
Part #: 12085270
Order #: J-38125-6
Cabinet (Holds 5 trays)

7 each
Order #: J-38125-610
CRIMPER - A thru E
Part #: 12085271
J-Number: J-38125-7
CRIMPER - F&G - Sealed Splice

Part #: 12085115
J-Number: J-38125-8
50
Reference Guide
Order #: J-38125-620H
TERMINALS AND CONNECTORS

AFL/EPC Connectors
Production connector design
Service connector design
12085271 / J-38125-7
12085270 / J-38125-6
12094429 / J-38125-12A
12094429 / J-38125-12A
51

Bosch
Bosch Connector Identification
Bosch connectors can be identified by one of three possible markings:
1. The word Bosch may be molded into the connector.
2. The Bosch symbol may be located on the connector.
3. The letters BK may be visible on the connector.
52

Bosch Sensor Connector (BSK)
280 BSK Sealed

LOCK TANGS
INSULATION
WINGS
CORE WINGS
12085271 / J-38125-7
CABLE SEAL
12085270 / J-38125-6
J-38125-561
J-38125-561
53

Junior Power Timer (JPT)
LOCK TANGS
CORE WINGS
INSULATION
WINGS
ENTRY CANAL
12085271 / J-38125-7
12085270 / J-38125-6
12093647 / J-38125-556
12093647 / J-38125-556
54

.64 Connector
TPA
Connector w/ .64 round terminal

PRIMARY LOCK TANG
Terminal release tool inserted into connector
15314260 / J-38125-560
15314260 / J-38125-560
55

Bosch ECM Connector
Remove cover with latch and TPA
prior to removing terminal(s).
The cover with latch is keyed to the connector.

Use caution when installing the cover, making
sure the cover is properly indexed.
Typical Configuration, NOTE: The connector

shown on the left is removed first.
ENTRY CANAL
J-38125-643
J-38125-213
J-38125-213
56

Delphi Automotive Systems
Delphi Connector Identification
Delphi connectors can be identified by the letters PED (Packard Electric Division) or
DELPHI molded into the connector body.
57

Edgeboard
PRIMARY LOCK
TANG
Edgeboard Female
12094429 / J-38125-12A
12085271 / J-38125-7
58

Weather Pack
CORE WINGS
INSULATION
WINGS
SEAL
12085271 / J-38125-7
12014012-1 / J-38125-10A
12014012-1 / J-38125-10A
59

Metri-Pack 150 Series
INSULATION
WINGS
CORE WINGS
SEAL
ENTRY CANAL
12085271 / J-38125-7
12094429 / J-38125-12A
12094429 / J-38125-12A
60

INSULATION
WINGS
CORE WINGS
Metri-pack 280 Series Female Sealed
12094430 / J-38125-11A
12085270 / J-38125-6
61

Metri-Pack 280 Series (Tangless)
INSULATION
WINGS
CORE WINGS
Metri-pack 280 Series Tangless
TPA
12094430 / J-38125-11A
12085271 / J-38125-7
62

Metri-pack 480 Series
12094430 / J-38125-11A
12085271 / J-38125-7
63

Metri-pack 630 Series Female (pull to seat)
12094430 / J-38125-11A
12085271 / J-38125-7
64

Micro-Pack 100
PRIMARY LOCK
TANG
M/P 100W Female
12031876-1 / J-38125-13A
12085271 / J-38125-7
65

Micro-Pack 100W Tangless
TPA
INSULATION
WINGS
CORE WINGS
Tangless 100W Female Sealed
12122523 / J-38125-33
12125080 / J-38125-101
66

Micro-Pack 100W Tangless (2.54mm Center Line [CL])
INSULATION
WINGS
CORE WINGS
TPA COVER
100W Series Female
12094429 / J-38125-12A
12125080 / J-38125-101(W)
67

Micro-Pack 100W Tangless Connectors/Terminals Compared
3.0CL
Terminals are of different lengths
2.54 CL
Grey TPA from 2.54mm CL Connector
68

Flexbeam
FBT Sealed Terminals
ENTRY CANAL
NOTE: Position of dot on tool faces away

from the terminal being removed.
ENTRY CANAL
12085271 / J-38125-7
12085270 / J-38125-6
J-38125-29
J-38125-29
69

Micro .64
Micro .64
ENTRY CANAL
15381651-2 / J-38125-21
15397700 / J-38125-64
70

Delphi In-Line .64 Connector System
ENTRY CANAL
.64 MALE
.64 FEMALE
ENTRY CANAL
15381651-2 / J-38125-21
15389891 / J-38125-22
J-38125-643
71

Terminal Probing
ALWAYS USE THE CORRECT PROBE FOR
TERMINAL TESTING
HANDLING THE .64mm TERMINAL
When probing a terminal for testing procedures it is

imperative to use the J-35616-D Terminal Test Kit.
Not using the proper test kit probe may cause
damage to the terminal(s) being probed. The
terminal probes in the kit are sized to fit the
various terminal sizes and shapes properly.
Terminals are becoming increasingly smaller
and more complex in design. Using an
instrument other than the correct probe will, in
most cases, cause irreversible damage to the
terminal by enlarging it to the point that it will
no longer mate correctly. This can lead to open
circuit or intermittent concerns and the creation
of a customer concerns that did not exist
before testing began.
The .64mm round terminal is the most prone to

damage caused by incorrect probing because
of its small size. The most common mistake
made while testing the .64mm terminal is the
use of the wrong probe. The J-35616-6 (Brown)
probe is most widely mistaken for use in the
.64mm terminals. The J-35616-6 probe is
actually a 1.00mm probe, but from a distance
looks similar in size to a .64mm probe. The
correct probe for this size of terminal is the J35616-64B.
It is not recommended to use Digital Multi

Meter probes directly on a terminal.
As shown above, the DMM probe is considerably

larger than a typical terminal probe.
The .64mm probe has gone through a number

of revisions. First was the J-35616-64, this probe
was designed without a pigtail, making it too
wide to allow probing of side by side terminals
in the same connector. The second version was
the J-35616-64A, and incorporated a white pigtail
that allowed for side by side terminal probing.
The third version was also J-35616-64A, which
included a light blue pigtail and incorporated a
more robust Male Terminal.
ALL OF THE PREVIOUS PROBES
SHOULD BE DISCARDED!
72

Terminal Probing (continued)
Female Terminal
The current .64mm probe is the J-35616-64B,

and can be easily identified by the Black pigtail
and gold plated terminal.
Mating Pin
USCAR Standard 0.64mm
Square or 0.8mm Round
2 Moving Contacts
If a larger probe is used on any terminal, the

terminal may be damaged beyond use. The
damage may not be noticeable right away,
however, when the connectors are re-connected
the mating terminals may not fit together as
designed. This will likely result in an open, or
intermittent circuit condition. Always use the
correct probe when testing a circuit at a terminal.
The correct probe for any terminal can be found
in the crimp matrix in this book located on pages
105-132, and in GM SI Connector End View.
Stationary Contact
Standard Terminal Mated to a 0.64mm USCAR Pin
Stationary Contact
Orientation 1
Orientation 2
Standard Terminal Mated to a 0.64mm BOSCH Pin
NOTE: Terminal damage caused by using the

wrong test probe.
Orientation 1
73
Orientation 2

Hybrid Connector
15397700 / J-38125-64
15381651-2 / J-38125-21
15381651-2 / J-38125-21
74

Comb Style TPA Handling
Both Bosch and Delphi utilize the comb style TPAs on some of the Micro .64 connectors. Handling these types of
TPAs correctly is very important. If broken you can get a replacement (Delphi only) out of J-38125-605 Connector
Parts Tray. If broken inside of the connector it can be very difficult to remove the pieces to remove a terminal.
Comb Style TPA in a .64 Connector
75

Empire Connectors
Empire connectors are molded using existing Delphi connector designs. Utilize a Delphi replacement
connector, terminal and tools when servicing.
Note Empire logo
Empire Connector
Delphi Connector
Empire has no
entry canal
Delphi Entry Canal
Note Delphi logo
TPA must be removed prior

to releasing terminal
76

FCI Connectors
ENTRY CANAL
TPA is pulled up into the preset position

using J-38125-216. Do not remove the TPA.
Use J-38125-215A to release

terminal from connector
J-38125-216
J-38125-215A
J-38125-643
77

JST Connectors
Typical BCM Connectors
TPA locked
ENTRY CANAL
ENTRY CANAL
TPA in staged position
NOTE: TPA in staged position. TPA lifted approximately

1/16" prior to terminal being removed
ENTRY CANAL
Terminal removed from connector
78

JST Connectors cont.
12094429 / J-38125-12A
12085271 / J-38125-7
79

Kostal Connectors
12085271 / J-38125-7
12085270 / J-38125-6
J-38125-28
J-38125-28
80

Molex Connectors
ENTRY CANAL
TPA must be pulled up into its staged

position to allow terminal removal.
J-38125-213
J-38125-216
J-38125-641
81

Molex Connectors (continued)
ENTRY CANAL
TPA must be pulled up into its staged

position to allow terminal removal.
J-38125-213
J-38125-216
J-38125-641
82
Page 82

Sumitomo
Sumitomo Connector Identification
Sumitomo connectors can be identified by the Sumitomo TM symbol molded into
all Sumitomo connectors.
83

ABS Connector
.500 and .64 Terminals
ENTRY CANAL
TPA
Hybrid (2-different size terminals) ABS Connector
J-38125-642
12085270 / J-38125-6
12094430 / J-38125-11A
12085271 / J-38125-7
12094429 / J-38125-12A
84

Bussed Electrical Center (BEC) Connector
12094429 / J-38125-12A
12094430 / J-38125-11A
12085271 / J-38125-7
85

Door Connector
Pillar Half
Door Half
Both have hybrid multiple size terminals 280 and 150.
COVER RELEASE
Remover cover for access to cable

and rear of connector.
COVER
ASSY.
CPA
HANDLE
WEATHER
SEAL
86

Door Connector (continued)
Pull TPA to remove
Use release tool to pry terminal lock tang

away from terminal to release.
Hybrid Terminals
12094429 / J-38125-12A
87

Connector half houses male terminals.
Push up on opposite corners of TPA to rock

it loose and remove.
TPA lock tangs located on opposing corners.
88

280 Terminal
12094429 / J-38125-12A
12085271 / J-38125-7
89

Tyco Connectors
Tyco Connector Identification
The name tyco or Amp can be found molded into the body of the connector or on the TPA.
90

Tyco JPT Connector
ENTRY CANAL
ENTRY CANAL
J-38125-221
12085271 / J-38125-7
91

Tyco Connector
ENTRY CANAL
ENTRY CANAL
12085271 / J-38125-7
12085270 / J-38125-6
J-38125-36
J-38125-36
92

Tyco Hybrid Connector
630
.64
Hybrid Connector
630 and .64mm terminals.
TPAS
COVER
Both TPAs (blue) must be pryed

up to release terminals.
SEALED
CABLE
12094430 / J-38125-11A
12094429 / J-38125-12A
J-38125-642
12085270 / J-38125-6
12085271 / J-38125-7
93

Tyco Hybrid Connector w/Lever CPA
Hybrid Connector
(cover is missing in pic)
RELEASE
TOOL
ACCESS
RELEASE
TOOL
ACCESS
TPA must be fully removed

to remove terminals
15315247 / J-38125-553
J-38125-641
12085271 / J-38125-7
94

Lever Assisted Connector
COVER
TERMINAL
CARRIER
RELEASE
CPA LEVER
TERMINAL CARRIER
Connector with lever actuated CPA.
Once released the terminal carrier slides

out from the rear of the connector.
The terminal carrier must be removed to disengage

and remove the terminals.
95

Lever Assisted Connector (continued)
Lifting on the terminal lock tang

releases the terminal
.64
J-38125-641
12094429 / J-38125-12A
12094429 / J-38125-12A
96

SDM Connector
COVER
Terminal and cable come as a terminated lead

which is spliced into the harness.
CPA
HANDLE
TPA is completely removed to access terminals.
TERMINAL
LOCK TANG
15315247 / J-38125-553
12085115 / J-38125-8
Crimp and seal splice is used
to apply terminated lead.
97

6-way Connector
SEAL
6-way Connector
CORE WINGS
INSULATION
WINGS
CABLE
SEAL
TPA in Locked
Position
TPA
TPA in Open
Position
Push in on the lock

tab to remove
terminal.
NOTE: There is one

TPA on each side of
the connector. Both
must be closed for
the connector to
be installed.
12094429 / J-38125-12A
J-38125-642
98

Side Load TPA
TPA
TERMINAL RELEASE
TOOL ENTRY CANAL
99

Side Load TPA (continued)
TPA in locked position
TPA in released position,

terminals can be removed
TPA
.64
TPA
J-38125-641
15315247 / J-38125-553
100

Yazaki
Yazaki Connector Identification
Yazaki connectors can be identified by the Yazaki TM symbol that is molded into
all Yazaki connectors or a connectors accompanying TPA.
101

Type 1 Connectors
Yazaki connectors are designated by the type of Terminal Position Assurance (TPA) they
utilize. There are three versions of connectors currently used by GM. Type 1 which uses
a front loading TPA, type 2 which uses a side loaded TPA and type 3 which uses a locking
device at the rear of the connector.
INSULATION
WINGS
CORE
WINGS
280 YESc Unsealed Female
ENTRY
CANAL
TPA
12094430 / J-38125-11A
12085271 / J-38125-7
102

Type 1 Connectors (continued)
This style of Yazaki connector utilizes a seal at the rear of the connector body. Remember
to apply the seal to the wire prior to crimping a new terminal on. Be sure that the seal is not
damaged when crimping the insulation wings and be sure it has a good fit into the back of
the connector body.
SEAL
CORE WINGS
ENTRY
CANAL
INSULATION
WINGS
TPA
J-38125-216
12085271 / J-38125-7
12085270 / J-38125-6
103

The TPA on this style of Yazaki connector has a series of stops molded into the body of the
connector along the side. The TPA should be removed completely to allow the release tool
access to the terminal lock tang. As with all TPAs, always reposition the locking device when
completing a repair.
INSULATION
WINGS
CORE WINGS
280 YESC Unsealed Male

TPA
12094430 / J-38125-11A
12085271 / J-38125-7
104

CORE WINGS
ENTRY
CANAL
INSULATION
WINGS
TPA
12094430 / J-38125-11A
12085271 / J-38125-7
12085270 / J-38125-6
105

26 p 150+280+630 YESC Unsealed Female
12094430 / J-38125-11A
12085271 / J-38125-7
106

CORE WINGS
INSULATION
WINGS
10p 150 YESC Sealed Male
TPA
12094430 / J-38125-11A
12085271 / J-38125-7
107
SEAL

SEAL
CORE WINGS
ENTRY
CANAL
INSULATION
WINGS
TPA
12094430 / J-38125-11A
12085271 / J-38125-7
108
107

14p 150+280 YESC Unsealed Female
ENTRY
CANAL
TPA
12094430 / J-38125-11A
12085271 / J-38125-7
109

Type 2 Connectors
15315247 / J-38125-553
12085271 / J-38125-7
110

Type 3 Connectors
CORE WINGS
7114-3250
INSULATION
WINGS
REAR
HOLDER
12094430 / J-38125-11A
12085271 / J-38125-7
111
Service
Terminal
Number
60000511
60000611
60000631
60000641
60012811
60012911
60012931
60012941
60040431
60040441
60040451
60040461
60992604
60992607
60993906
60993913
60993928
60993934
60994015
60994023
60994034
JW-1630-2
PG-1209-31
PG-1809-2
Page 112
150 DCS II female

150 DCS II female sealed
280 DCS II female
280 DCS II female
480 DCS II cable seal - Yel.
480 DCS II cable seal - Grn.
150 DCS II cavity plug - Wht.
150 DCS II cable seal - Red
150 DCS II cable seal - Gry.
280 DCS II cable seal - Blu.
280 DCS II cable seal - Red - Brn.
630 Faston female
250 round female
250 round female
Description
J-38125-560
15314260
15314260
J-38125-560
12122378
J-38125-557
J-38125-557
J-38125-557
12093647
12093647
12093647
12093647
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
12094430
12152110
12152110
Terminal
Removal
Tool
Insulation Crimp
C
8
E
8
2
C
A
D
A
D
A
D
4
8
C
8
3
3
3
3
3
3
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
AFL Tray 21
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-40 (BU)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
J-35616-42 (RD)
J-35616-37 (L-BU)
J-35616-37 (L-BU)
Test Probe
Service
Terminal
Number
01839906
02962516
02971962
02973216
02984172
02984375
05297428
08911640
12004996
12020320
12020321
12033816
12034037
12048247
12089189
12089190
12089191
12089507
12124515
12124580
12124582
12129497
12191475
88988379
Page 113
Splice Clip - Unsealed

Pin Grip female
56 series long male
59 series straight female
Ring Terminal Serrated - straight 6mm
Ring Terminal Serrated - straight 5mm
Pac/on I female
Pac/on II female
Pac/on I male
Pac/on III female
Pac/on I male
Obsolete
Mic/P 100 female
Splice Seal - Salmon
Splice Seal - Blue
Splice Seal - Yellow
P/C Bow female
56 series female
W/P female sealed
W/P male sealed
M/P 280 series male
M/P 280 series female
Splice Seal - Green
Description
N/A
12094430
12094430
12094430
N/A
N/A
N/A
12094429
12094429
12094429
12094430
12094430
N/A
12031876-1
N/A
N/A
N/A
12094429
12094430
12014012-1
12014012-1
12094430
12094429
N/A
Terminal
Removal
Tool
Insulation Crimp
E
C
E
C
C
E
x
C
E
x
E
C
F
C
C
C
C
F
C
C
C
C
E
C
F
C
C
A
C
C
C
E
x
E
C
2
2
2
4
C
C
A
C
C
C
E
G
A
A
C
A
A
A
2
2
2
4
A
A
A
A
C
G
A
A
F
A
A
A
2
2
2
A
A
A
A
A
A
G
A
F
F
F
F
4
4
F
A
4
4
F
A
A
A
G
F
F
F
F
F
A
A
G
F
F
F
F
F
x
A
D
A
D
A
A
A
A
A
A
A
D
A
A
A
A
A
A
A
D
A
A
A
D
D
A
A
A
D
5
5
5
G
D
D
D
D
D
A
A
D
F
B
D
D
D
5
5
5
G
D
D
D
B
D
D
F
F
D
D
D
5
5
5
G
D
B
D
B
D
D
G
F
G
G
5
5
5
G
B
B
G
G
G
G
G
5
5
5
G
B
B
G
G
G
G
G
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 1
N/A
J-35616-5 (PU)
J-35616-43 (RD)
J-35616-42 (RD)
N/A
N/A
N/A
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-41 (BU)
J-35616-4A (PU)
J-35616-41 (BU)
N/A
J-35616-6 (BN)
N/A
N/A
N/A
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-8 (OG)
J-35616-9 (OG)
J-35616-5 (PU)
J-35616-4A (PU)
N/A
Test Probe
Service
Terminal
Number
12015870
12020116
12020120
12020126
12033820
12034046
12034047
12041351
12045773
12047581
12048074
12048087
12048159
12048441
12048451
12066132
12066214
12077411
12084595
12089340
12103881
12124304
12129493
15326030
Page 114

M/P 280 series male
M/P 480 series male
M/P 630 series male
M/P 280 series male
M/P 280 series & W/P cable seal - Tan
M/P 150 series male sealed
M/P 150 series male
M/P 150 series female sealed
M/P 150 series cable seal - Blue
M/P 480 series cable seal - Wht.
Mic/P 100 female sealed
M/P 150 series female pull to seat
Description
12094430
12094430
12094430
12094430
12094430
12094430
12094430
N/A
12094429
12094429
12094429
N/A
12094430
N/A
12094430
12031876-1
12094430
12094430
12094430
12180559-1
12180559-1
12094430
12094430
12094429
Terminal
Removal
Tool
Insulation Crimp
E
E
E
2
C
E
E
E
E
E
E
E
2
C
E
E
E
E
E
E
E
2
E
E
2
E
E
E
E
E
E
C
E
E
E
E
E
E
C
C
C
E
E
F
F
E
F
2
2
E
2
C
C
C
C
C
C
A
4
A
A
A
A
A
A
A
A
1
C
1
A
A
C
C
5
E
1
C
1
A
A
C
C
5
E
1
C
1
A
A
C
C
5
E
1
A
1
A
A
A
A
A
C
C
D
3
E
D
5
1
A
1
D
D
D
D
D
D
D
D
D
D
B
5
D
D
D
D
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 2
J-35616-42 (RD)
J-35616-5 (PU)
J-35616-41 (BU)
J-35616-43 (RD)
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-5 (PU)
N/A
J-35616-3 (GY)
J-35616-3 (GY)
J-35616-14 (GN)
N/A
J-35616-5 (PU)
N/A
J-35616-40 (BU)
J-35616-6 (BN)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-40 (BU)
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-14 (GN)
Test Probe
Service
Terminal
Number
12015869
12020758
12040502
12040511
12048086
12059168
12064736
12066493
12084590
12084596
12089040
12089188
12089678
12103114
12103325
12110502
12146447
12160223
12160551
12160776
12161184
12176387
12176860
12191448
Page 115

Mic/P 100 female
P/C Bow female
P/C Bow female
M/P 150 series cable seal - Dk Red
M/P 150 series cavity plug - Dk Red
M/P 630 series male
W/P male sealed
W/P female sealed
M/P 150 series cable seal - Wht.
Mic/P 100 female
M/P 150 series male
Mic/P 100 female
Mic/P 100W male
Micro .64 female
Description
12094430
12094429
12094429
12094429
N/A
N/A
12094430
12094430
12094430
15315247
12014012-1
12014012-1
N/A
12031876-1
12094430
12094429
12031876-1
12094429
12122523
12180559-1
12180559-1
12094430
12180559-1
15315247
Terminal
Removal
Tool
Insulation Crimp
E
E
E
E
C
C
E
E
E E E
E E C C
E E E E E
E E
E E E E 2
W W W W
E E E E
E E E C
E
E
E
E
E
E
E
E
E
E
E
F
F
F
G/F
F
F
B
G/F
B
B
B
G/F
C
C
1
W
C
A
A
C
A
C
C
1
W
C
C
5
5
A
A
A
A
A
5
5
D
D
D
A
5
5
D
D
1 1 1
W W
C C
C C A
A
A
C
5
5
D
D
3
G
G
3/G
3
G
G
3/G
3
G
G
3/G
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 3
J-35616-42 (RD)
J-35616-6 (BN)
J-35616-4A (PU)
J-35616-4A (PU)
N/A
N/A
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-9 (OG)
J-35616-8 (OG)
N/A
J-35616-6 (BN)
J-35616-42 (RD)
J-35616-3 (GY)
J-35616-6 (BN)
J-35616-14 (GN)
J-35616-7 (BN)
J-35616-64B (L-BU)
J-35616-14 (GN)
J-35616-4A (PU)
J-35616-14 (GN)
J-35616-40 (BU)
Test Probe
Service
Terminal
Number
12015858
12015860
12077413
12084586
12110652
12110657
12110842
12110844
12110845
12110847
12110853
12160643
12160644
12177150
12191316
1241818-1
13525969
13525970
15305000
15324989
15336703
15359541
15366021
15410621
Page 116

M/P 280 series male
M/P 280 series female Buss Bar
480 SPT female
GT 280 series female
220 090 Series II cable seal - Dk. Red
GT 630 series cable seal - Red
M/P 800 series cable seal - Blu.
Micro .64 female
GT 150 series cable seal - Wht.
Micro .64 female
Description
12094430
12094430
12094430
12094430
15315247
15315247
15315247
15315247
15315247
15315247
15315247
12094429
12094429
12094429
12094430
12093647
15315247
15315247
N/A
N/A
N/A
15381651-2
N/A
15381651-2
Terminal
Removal
Tool
Insulation Crimp
E
F
A
F
F
B
F
F
F
F
F
F
F
F
B
B
B
B
F
B
B
M M
F
A
4
F
A
M M
2
A
F
C
C
C
M M M M
M M M M
1
D
A
A
B
3
4
G
B
G
3
D
G
G
D
G
G
5
G
G
G
5
G
5
G
G
G
5
G
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 4
J-35616-4A (PU)
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-5 (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-3 (GY)
J-35616-4A (PU)
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-4A (PU)
N/A
N/A
N/A
J-35616-64B (L-BU)
N/A
J-35616-64B (L-BU)
Test Probe
Service
Terminal
Number
12064971
12065915
12066638
12084912
12084913
12089263
12089496
12092344
12092345
12110063
12110064
12124075
12124471
12186456
12186457
15326427
15326429
15373403
15393149
15393150
15476168
15489500
15496302
8905087
Page 117

LP Socket sealed
Mic/P 100W female
Mic/P 100W female
Ring & Washer - straight 6mm
Ring & Washer - straight 6mm
M/P 280 series male ACT
M/P 280 series male ACT
LP Socket sealed
M/P 280 series female ACT
M/P 280 series female ACT
GT 150 series female sealed
GT 150 series male sealed
GT 150 series male
Micro .64 male
Pac/on I female
Description
12094429
12150860
12180559-1
12122523
12122523
N/A
N/A
12094429
12094429
15315247
15315247
12180559-1
12094430
12094429
12094429
15315247
15315247
15315247
15315247
15315247
15315247
15389891
15315247
12094429
Terminal
Removal
Tool
Insulation Crimp
C
2
E
C
2
C
2
E
E
2
C
K
2
C
E
E
E
E
E
E
K
E
C
E
E
E
E
E
E
E
2
E
2
E
2
K
2
C
C
2
E
E
2
C
E
2
2
C
E
2
C
C
2
C
F
F
C
2
C C
2 2
W
W W W W
A
A
A
A
F
F
F
F
C
A
5
A
5
C
A
4
4
C
C
C
3
K
A
A
C
A
4
4
4
C
C
3
K
A
A
A
1
1
1
4
A
C
3
K
A
A
A
1
1
1
4
A
C
3
A
D
1
4
A
A
1
A
D
D
A
3
A A
5 5
W
W W W W
D
D
D
D
B
B
B
B
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 5
J-35616-14 (GN)
J-35616-44 (YE)
J-35616-4A (PU)
J-35616-6 (BN)
J-35616-6 (BN)
N/A
N/A
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-14 (GN)
N/A
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-2A (GY)
J-35616-2A (GY)
J-35616-3 (GY)
J-35616-3 (GY)
J-35616-2A (GY)
J-35616-42 (RD)
J-35616-65B (L-BU)
J-35616-2A (GY)
J-35616-4A (PU)
Test Probe
Service
Terminal
Number
12020156
12033997
12064734
12084449
12177068
12177069
12191819
15304711
15304716
15304717
15304722
15304724
15304728
15304729
15304732
15305171
15305174
15496531
1928498054
1928498055
1928498056
1928498057
1928498058
1928498132
Page 118

Mic/P 100 male
280 Mini-Timer female
280 Mini-Timer female
GT 280 series male
GT 280 series male
GT 150 series cavity plug Grn.
Mic/P 064 female sealed
GT 150 FBT series female sealed
280 BDK female sealed
120 MAT female
Description
12094430
12094430
12094430
12094429
12093647
12093647
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
N/A
12180559-1
J-38125-29
J-38125-561
J-38125-561
J-38125-561
J-38125-561
J-38125-561
J-38125-213
Terminal
Removal
Tool
Insulation Crimp
E
E
E
E
2
E
E
E
J
E
E
E
E
E
E
E
E
E
E
E
E
E
J
E
E
E
E
E
E
E
2
2
2
E
J
E
2
E
E
2
E
2
2
2
C
E
C
2
E
2
E
2
E
K
2
2
C
C
E
C
4
2
2
2
C
C
A
2
4
2
4
C
A
C
4
C
4
A
4
A
1
A
A
A
1
1
J
1
A
1
A
A
1
3
A
A
1
J
1
A
1
1
A
1
3
A
A
1
J
1
A
1
C
A
1
1
A
1
3
A
A
A
1
5
1
5
1
K
A
1
1
3
A
A
1
1
A
1
1
1
1
1
D
1
5
1
1
D
D
1
5
1
5
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 8
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-43 (RD)
J-35616-7 (BN)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-2A (GY)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-5 (PU)
N/A
J-35616-64B (L-BU)
J-35616-2A (GY)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-16 (L-GN)
Test Probe
Service
Terminal
Number
12010300
12015878
12020634
12034110
12047698
12052139
12052172
12052386
12059255
12065196
12065892
12066082
12066337
12077939
12092445
12103359
12103503
12103504
12103506
12103507
12103512
15304725
15305170
821240
Page 119
M/P 280 series cavity plug - Grn.

56 series short male
M/P 800 series female side angle
Pin series female
M/P 630 series cable seal - Grn.
M/P 280 series male pull to seat
M/P 150 series female R/angle
Ring Terminal - straight 10mm
GT 280 series male
GT 280 series cavity plug Wht.
Description
N/A
12094430
12150860
12094430
12094429
12094430
12094430
N/A
N/A
12094430
12094430
N/A
12094429
12180559-1
12150860
12094429
N/A
N/A
N/A
N/A
N/A
12094430
N/A
N/A
Terminal
Removal
Tool
Insulation Crimp
E
E
E
E
B
A
G
F
C
C
F
4
A
A
E
E
A
A
A
4
F
4
A
A
4
4
F
A
G
G
F
D
G
A
G
G
F
D
G
A
G
G
F
F
A
A
A
A
B
B
A
A
3
F
D
B
4
A
3
F
F
B
3
F
F
B
3
B
G
B
G
G
3
3
G
B
G
G
3
3
G
B
G
G
3
3
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 18
N/A
J-35616-43 (RD)
J-35616-44 (YE)
J-35616-42 (RD)
N/A
J-35616-40 (BU)
J-35616-41 (BU)
N/A
N/A
J-35616-41 (BU)
J-35616-40 (BU)
N/A
J-35616-5 (PU)
J-35616-4A (PU)
J-35616-44 (YE)
J-35616-14 (GN)
N/A
N/A
N/A
N/A
N/A
J-35616-5 (PU)
N/A
N/A
Test Probe
Service
Terminal
Number
12103514
12110127
12124313
12129484
12129960
12146448
12147300
12147303
12176636
12177007
12191812
15304702
15304713
15304719
15304720
15304731
15305100
15305180
15324340
15326267
15326269
15326592
1928498135
Page 120

220 090 series II female
Mic/P 100 female
150 Ducon male
150 Ducon female
Mic/P 064 female
GT 150 series male
220 090 series II male
.64 090 series female
.64 Ducon female
120 MAT female
Description
N/A
12150860
12094430
12094429
12094429
12031876-1
12094429
12094429
12094429
12180559-1
15315247
15315247
15315247
15315247
15315247
15315247
12094429
12094429
12094430
15315247
15315247
12094429
J-38125-213
Terminal
Removal
Tool
Insulation Crimp
A
A
A
A
E E C C 2
A/E A/E C C C
A/2 A/2 A/2 A/2 A/C
A A
E E E E
E E E E E
E E E E E
J J J K
E
C
E
A
A
C
C
2
E E E
E E E E
A/E A/E A/E C
E E E E
A
A/C A/C A/C
C C C C
E E
E E C C
E E 2 2
4
4
2
5
A
A
1
2
C
C
C
A
C
4
4
2
J
5
A
A
A
1
2
C
4
A
C
A
C
1
1
C
J
5
A
A
A
4
A
1
A
A
A
C
1
1
C
J
5
A
A
A
4
A
A
A
C
A
A
1
1
C
K
5
A
A
F
A
4
A
A
A
B
A
1
B
B
B
B
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 19
N/A
J-35616-44 (YE)
J-35616-4A (PU)
J-35616-14 (GN)
J-35616-18 (BK)
J-35616-6 (BN)
J-35616-3 (GY)
J-35616-2A (GY)
J-35616-14 (GN)
J-35616-64B (L-BU)
J-35616-2A (GY)
J-35616-3 (GY)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-5 (PU)
J-35616-19 (BK)
J-35616-64B (L-BU)
J-35616-4A (PU)
J-35616-2A (GY)
J-35616-3 (GY)
J-35616-64B (L-BU)
J-35616-16 (L-GN)
Test Probe
Service
Terminal
Number
08-50-0115
15336748
15355438
15355486
15366022
15366065
15366067
15435885
16-02-1110
39-00-0077
43375-0001
44476-1111
IL-AG5-C1-5000
IL-AG5-PC1-5000
SAITW-A03T-064
SHCM-A03T-P025
SHCMW-A03T-040
SNAC3-A021T-M0.64
SNAC3-A031T-M0.64
SNAC-A03T-M040
SNAC-A061T-M2.8
SNAC-A081T-M2.8
SNAC-A091T-M2.8
SVH-21T-P1.1
Page 121
280 KK female
100 040III series female
100 040III series male
Mic/P 064 series cable seal - Grn.
GT 280 series cable seal - Org.
GT 280 series cable seal - Tan
Mic/P 100W female
.64 SL female
130 Mini-Fit female
280 Mini-Fit female
130 Mini-Fit female
.64 female
.64 male
.64 AIT-W male
.64 female
100 male
.64 female
.64 female
100 female
280 female
280 female
280 female
220 female
Description
J-38125-213
12150860
15315247
15315247
N/A
N/A
N/A
12122523
J-38125-213
J-38125-560
12094429
J-38125-560
J-38125-211
J-38125-211
J-38125-215A
12094429
12094429
12094429
12094429
12094429
12094429
12094429
12094429
12094429
Terminal
Removal
Tool
Insulation Crimp
K
C
E
E
E
J
E
K
J
J
J
J
J
J
J
J
E
K
K
K
J
J
J
J
C
C
G/F
C
C
C
K
K
K
J
J
J
J
K
J
J
J
J
J
J
J
J
A
W W
H
W W
H
E
C
C
E E
C/E C/E
K
A
D
B
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 20
J-35616-4A (PU)
J-35616-44 (YE)
J-35616-16 (L-GN)
J-35616-17 (L-GN)
N/A
N/A
N/A
J-35616-6 (BN)
J-35616-64B (L-BU)
J-35616-12 (BU)
J-35616-4A (PU)
J-35616-12 (BU)
J-35616-64B (L-BU)
J-35616-65B (L-BU)
J-35616-65B (L-BU)
J-35616-64B (L-BU)
J-35616-17 (L-GN)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-16 (L-GN)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-18 (BK)
Test Probe
Service
Terminal
Number
15305172
15305232
15344769
15366061
15366063
15392777
15410292
15445905
33001-1004
33012-1003
33088-0007
33088-0013
33093-0005
33093-0007
33116-0003
33118-0005
33467-0003
33467-0005
33468-0001
33468-0003
39-00-0038
39-00-0046
43030-0010
Page 122
GT 280 series cavity plug Tan

RT 630 series female
GT 280 series cable seal - Dk. Red
GT 280 series cable seal - Gry.
GT 630 series male
Micro 100 HVT female
150 MX female
150 MX female
150 Micro round female
150 Micro round male
.64 MX female
.64 MX female
.64 MX female
.64 MX female
130 Mini-Fit female
130 Mini-Fit female
.64 Micro-Fit female
Description
N/A
12094430
12094430
N/A
N/A
15315247
15315247
12180559
J-38125-217
J-38125-217
12152110
12152110
12152110
12152110
12152110
12152110
J-38125-213
J-38125-213
J-38125-213
J-38125-213
J-38125-560
J-38125-560
J-38125-213
Terminal
Removal
Tool
Insulation Crimp
K
H
H
J
K
J
K
K
K
K
K
J K K
E A/E A/E
2/E 2/E
E
C
C
E
B/4 B/4 B/4 B/4 F
F
F
F
F
B
F
B
F
C
C
D B B
G/F G/F G/F G/F G/F
F
F
K
H
H
2
C
J
K
K
K
K
K
A
A
J K K
2 A/C A/C
2
3
B
3
B
3
G
A
A
5 5
G/1 G/F G/F G
3
B
5
G
3
G
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 23
N/A
J-35616-42 (RD)
J-35616-42 (RD)
N/A
N/A
J-35616-4A (PU)
J-35616-43 (RD)
J-35616-16 (L-GN)
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-66 (YE)
J-35616-66 (YE)
J-35616-67 (YE)
J-35616-67 (YE)
J-35616-55 (TN)
J-35616-54 (TN)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-12 (BU)
J-35616-12 (BU)
J-35616-64B (L-BU)
Test Probe
Service
Terminal
Number
12033605
12110700
12147451
12147474
12158098
1438232-4
15324983
15324995
154717-3
15484100
15491972
160366-2
170089-1
170325-1
172773-1
180351-2
1928498059
2153-006
60295-2
62050-1
638187-2
643221-2
927852-8
963898-3
Page 123
P/C Bow female

280 Ducon female
630 Ducon female sealed
280 Ducon female sealed
180 Mini-blade female
M/P 280 series cable seal - Dk. Red
M/P 630 series cable seal - Dk Red
630 Posi-Lock MK I female
280 Faston female
630 Faston female
480 Posi-Lock female
180 MIC female
630 Faston female
500 Box Type female
630 Faston female
280 Faston female
.64 AMP female
280 JPT female
150 Micro-Timer male
Description
12094429
12150860
12094430
12094430
12094430
12094429
N/A
N/A
12094429
12094430
15315247
12094429
12094430
J-38125-218
15315247
12094430
J-38125-561
12094430
12094430
12094429
12094429
15315247
12094429
J-38125-560
Terminal
Removal
Tool
Insulation Crimp
2
E
E
E
E
E
E
C
2
E
E
C
E
E
E
E
E
E
E
E
E
G
C
2
2
C
2
C
E
E
C
C
2
2
2
2
C
2
2
A
D D D
4 4
G/F G/B G/B
2 2 2
G/F G/F G/F G/F G/F G/F G/F
E C C C
C
5
2
A
C
4
A
A
A
C
5
2
4
A
A
A
C
5
A
A
4
A
A
4
C
5
A
A
A
D
4
5
4
3
1
A
3
5
A
3
5
D
5
G
3/5
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Delphi Tray 24
J-35616-4A (PU)
J-35616-45 (YE)
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-4A (PU)
J-35616-33 (YE)
N/A
N/A
J-35616-42 (RD)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-40 (BU)
J-35616-33 (YE)
J-35616-42 (RD)
J-35616-35 (VT)
J-35616-31 (OG)
J-35616-42 (RD)
J-35616-4A (PU)
J-35616-64B (L-BU)
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-3 (GY)
Test Probe
Service
Terminal
Number
1123343-2
154718-3
171631-2
171661-5
1719532-5
172748-1
173630-7
173716-1
184030-1
184095-1
184139-1
184140-1
184141-1
1-968857-3
1-968859-3
280756-4
282224-1
282225-1
2-927835-2
2-968037-4
771016-HK200
771416-HK200
771816-HK200
963716-2
Page 124
.64 Multi-Lock female

180 Econoseal male sealed
180 Econoseal male sealed
.64 MQS female
180 Econoseal cavity plug - Blk.
180 Multi-Lock female
180 AMP SSC female sealed
180 AMP SSC female sealed
180 AMP SSC cable seal - Lt Blu.
180 AMP SSC cable seal - Brn.
180 AMP SSC cable seal - Ppl.
280 MCP female sealed
280 MCP female sealed
950 Faston female
180 Econoseal female sealed
480 SPT female sealed
480 SPT female sealed
280 series female
280 series female
280 series female
.64 MQS male
Description
J-38125-24
12094429
12094429
12094429
12094429
N/A
15315247
15315247
12094429
12094429
N/A
N/A
N/A
12093647
12093647
12094429
12094429
12094429
12093647
12093647
12094430
12094430
12094430
12094429
Terminal
Removal
Tool
Insulation Crimp
E
E
J
C
J
E
E
E
E
E
E
C
K
E
E
E
E
C
J
E
K
E
J
C
A
2
C
2
2
C
A
F
D
A
F
F
D
A
F
4
4
A
J
4
4
D
D
D
D
J
A
J
D
D
D
J
A
K
D
D
D
K
1
3
1
1
1
3
1
3
3
G
3
5
3
G
3
5
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Lear Tray 7
J-35616-64B (L-BU)
J-35616-42 (RD)
J-35616-34 (YE)
J-35616-34 (YE)
J-35616-64B (L-BU)
N/A
J-35616-33 (YE)
J-35616-16 (L-GN)
J-35616-33 (YE)
J-35616-33 (YE)
N/A
N/A
N/A
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-22 (RD)
J-35616-33 (YE)
J-35616-33 (YE)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-65B (L-BU)
Test Probe
Service
Terminal
Number
100132-1
33119-0004
4-964286-1
4-969005-1
638551-1
776001-1
828905-1
828985-1
828986-1
962943-5
963244-1
963245-1
963294-1
963530-1
963531-1
964274-2
964971-1
964972-1
967607-1
967608-1
Page 125
630 cavity plug - Blk.

150 2 peice female
280 JPT female sealed
160 Micro-Timer II female sealed
.64 AMP female
150 AMP DLC female
280 MCP cable seal - Wht.
250 MCP cable seal - Lt. Grn.
280 cavity plug - Brn.
160 Micro-Timer II female
630 MCP cable seal - Wht.
630 MCP cable seal - Yel.
280 JPT cable seal - Blu.
.64 Microtimer II cable seal - Gry.
150 Micro-Timer cavity plug - Wht.
.64 Micro-Timer II cable seal - Red
.64 Micro-Timer II cable seal - Yel.
480 PQL cable seal - Yel.
480 PQL cable seal - Grn.
Description
N/A
12152110
12093647
J-38125-560
15315247
15315247
N/A
N/A
N/A
J-38125-560
N/A
N/A
N/A
N/A
N/A
J-38125-560
N/A
N/A
N/A
N/A
Terminal
Removal
Tool
Insulation Crimp
E
E
J
E
K
E
E
K
E
E
E
K
E
E
E
1
1
J
C
1
1
K
C
K
C
K
C
C
1
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Lear Tray 16
N/A
J-35616-2A (GY)
J-35616-4A (PU)
J-35616-33 (YE)
J-35616-64B (L-BU)
J-35616-2A (GY)
N/A
N/A
N/A
J-35616-14 (GN)
N/A
N/A
N/A
N/A
N/A
J-35616-33 (YE)
N/A
N/A
N/A
N/A
Test Probe
Service
Terminal
Number
1241374-1
1241388-1
1241390-1
1241406-1
1326029-1
1326029-8
1326030-6
1326030-8
1456350-1
1488220-1
173681-2
1928498014
1928498016
344070-1
347707-1
62336-1
770678-1
776491-1
967652-1
968072-2
968074-2
968075-2
968121-2
968122-2
Page 126
150 AMP MCP female

280 MCP female
280 MCP female
630 MCP female
280 JPT male
280 JPT male
280 Power TImer female
280 Power TImer female
100 USCAR female
.64 AMP male
.64 BMK female
.64 BMK female
630 female sealed
630 Econoseal cable seal - Org.
280 Faston female
100 AMPSEAL cavity plug - Wht.
150 round female
480 PQL cavity plug - Clr.
480 PQL female
280 MPQ female sealed
280 MPQ female sealed
480 PQL female sealed
480 PQL female sealed
Description
J-38125-560
J-38125-557
J-38125-557
J-38125-557
J-38125-212
J-38125-212
12094429
12094429
J-38125-214
15315247
15315247
J-38125-560
J-38125-560
12094430
N/A
12094429
N/A
12094430
N/A
12031876-1
12031876-1
12031876-1
12031876-1
12031876-1
Terminal
Removal
Tool
Insulation Crimp
N
N
E
J
E
N
N
N
N
2
E
K
E
K
E
N
N
E
E
E
K
E
E
E
E
E
E
C
2
C
A
C
A
2
2
C
2
C
F
F
J
4
N
N
2
K
4
N
N
B
2
C
N
N
B
2
K
2
C
N
N
B
2
K
C
C
4
4
4
A
4
C
4
A
4
A
4
4
5
D
G
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Lear Tray 17
J-35616-14 (GN)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-16 (L-GN)
J-35616-65B (L-BU)
J-35616-16 (L-GN)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-42 (RD)
N/A
J-35616-4A (PU)
N/A
J-35616-66 (YE)
N/A
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-40 (BU)
J-35616-40 (BU)
Test Probe
Service
Terminal
Number
104479-9
1241380-2
1411553-1
1411560-2
1411590-1
144969-1
170258-1
2-964280-1
2-964284-1
4-964274-1
4-965999-1
770520-1
770903-1
770904-1
771116-HK200
771316-HK200
771716-HK200
772216-HK200
927837-1
927837-7
962928-1
963720-3
964328-1
967011-1
Page 127
.64 Modu female

150 AMP MCP female sealed
.64 ELO female
.64 ELO female
280 ELO female
.64 MQS female
630 Faston female
280 JPT female
280 JPT female
280 JPT female
100 AMPSEAL round female
100 Mini UMNL round male
100 Mini UMNL round female
280 series female
280 series female
280 series female
280 series female
480 SPT female
480 SPT female
950 Maxi-PT female
.64 Modu female
480 SPT female
480 SPT cable seal - Grn.
Description
J-38125-24
J-38125-560
12094429
12094429
15315247
12094429
12094430
12093647
12093647
J-38125-560
12093647
N/A
J-38125-220
J-38125-220
12094430
12094430
12094430
12094430
12093647
12093647
J-38125-221
J-38125-24
12094429
N/A
Terminal
Removal
Tool
Insulation Crimp
E
E
E
E
E
E
E
C
E
E
C
E
E
E
J
E
E
E
E
E
E
E
E
J
E
E
E
E
E
E
C
C
E
C
A
B
J
2
C
C
C
2
A
C
2
A
A
J
2
C
C
C
2
A
A
2
2
C
A
A
2
2
C
A
A
A
A
A
D
G
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Lear Tray 25
J-35616-64B (L-BU)
J-35616-14 (GN)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-4A (PU)
J-35616-64B (L-BU)
J-35616-42 (RD)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-14 (GN)
J-35616-4A (PU)
J-35616-6 (BN)
J-35616-7 (BN)
J-35616-10 (GN)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-22 (RD)
J-35616-64B (L-BU)
J-35616-42 (RD)
N/A
Test Probe
Service
Terminal
Number
08-50-0133
08-52-0071
1241402-1
1241408-1
1393457-1
1393457-2
1393457-3
1438299-4
170349-2
1743423-1
34083-1002
35421-6202
35421-6302
368087-1
368088-1
39-00-0059
49702-6702
50654-1001
50660-9001
57919-6702
57919-6802
57919-6902
927808-2
964265-2
Page 128
280 KK female
280 KK female
630 MCP female
630 MCP female
.64 ELO cable seal - Gry.
.64 ELO cable seal - Red
.64 ELO cavity plug - Wht.
.64 GET male
630 Faston male
280 MCP male
150 MX female sealed
220 Uniconn female
220 Uniconn female
220 Multi-lock male
220 Multi-lock male
130 Mini-Fit female
220 LIF female
100 SR female
100 SR male
220 LIF male
220 LIF male
220 LIF male
250 system round flag female
150 Micro-Timer male
Description
J-38125-213
J-38125-213
J-38125-557
J-38125-557
N/A
N/A
N/A
15315247
J-38125-212
J-38125-212
J-38125-217
12094429
12094429
15315247
15315247
J-38125-560
12094429
12094429
12094429
12094429
12094429
12094429
J-38125-222
J-38125-560
Terminal
Removal
Tool
Insulation Crimp
K
2
K
2
C
C
E
K
E
J
J
K
E
E
E
E
E
K
K
K
K
E
E
E
E
E E E C
E A/E A/E
E E E
K
2
E
K
J
J
J
J
E
E
E
H
K
C
C
2
K
J
J
J
J
E
2
2
H
K
C
2
2
K
2
J
J
K
E
2
2
D
K
A
C
C
K
K
A
D
A
K
A
C
C
K
K
A
D
A
K
A
A
A
A
4
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Lear Tray 28
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-42 (RD)
N/A
N/A
N/A
J-35616-65B (L-BU)
J-35616-43 (RD)
J-35616-5 (PU)
J-35616-14 (GN)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-12 (BU)
J-35616-18 (BK)
J-35616-16 (L-GN)
J-35616-17 (L-GN)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-37 (L-BU)
J-35616-34 (YE)
Test Probe
Service
Terminal
Number
7160-9465
7165-0347
7165-0348
7165-0349
7165-0356
7165-0395
7165-0547
7165-0796
7165-0797
7165-0815
8100-0461
8100-0468
8100-0544
8100-0594
8100-1466
8100-1467
8100-1710
8100-2493
8100-2512
8230-4040
8230-4282
8240-4140
8240-4422
Page 129
230 TS series cavity plug - Blk.

480 TS series cable seal - Dk. Grn.
280 cable seal - Gray
150 cable seal - Brn.
480 TS series cable seal - Dk. Blu.
230 TS series cable seal - Dk. Grn.
150 cable seal - Red
.64 TS series cable seal - Orn.
.64 TS series cavity plug - Gray
.64 TS series cable seal - Dk. Brn.
150 TS series female sealed
130 TS series female
.64 DL series female sealed
.64 DL series female sealed
100 DL series female
100 DL series male
630 HM series male
150 MT series male
630 HM series female
150 MT series female
Description
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
15315247
12094430
15315247
15315247
15315247
15315247
15315247
12094430
15315247
12094430
12094429
15315247
15315247
Terminal
Removal
Tool
Insulation Crimp
E
C
E
C
E
J
E
8
C
E
C
E
C
E
C
E
8
E
C
E
C
E
A
C
A
C
A
C
A
C
2
A
A
A
A
J
1
8
D
A
D
A
D
A
D
A
8
C
B
A
B
A
B
A
B
A
B
A
B
A
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Sumitomo Tray 6
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
J-35616-14 (GN)
J-35616-40 (BU)
J-35616-12 (BU)
J-35616-14 (GN)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-16 (L-GN)
J-35616-44 (YE)
J-35616-17 (L-GN)
J-35616-43 (RD)
J-35616-3 (GY)
J-35616-42 (RD)
J-35616-14 (GN)
Test Probe
Service
Terminal
Number
54001002
54001004
54001202
54001400
54001401
54001404
54001800
54001807
8100-3426
8100-3427
8100-3455
8100-4339
8100-4443
8100-4444
8100-4445
8240-0127
8240-0128
8240-4412
8240-4652
8240-4862
8240-4882
8240-4892
8240-4942
8240-4992
Page 130
280 APEX female

630 APEX female
280 APEX female
280 APEX female
280 APEX male
280 APEX female
280 APEX female
280 APEX female
.64 US series female
.64 US series female
.64 TS series female sealed
150 female
280 US series female
220 HX series female sealed
Description
12094429
12094429
12094429
12094429
12094429
12094429
12094429
12094429
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
Terminal
Removal
Tool
Insulation Crimp
K
8
E
E
E
E
E
E
E
E
E
7
E
E
E
E
E
C
C
2
2
C
C
2
2
2
2
2
E
C
4
2
2
2
2
2
6
D
6
D
C
C
C
7
C
A
1
C
C
C
C
C
K
8
C
A
A
A
A
A
A
A
A
A
A
4
4
1
1
D
4
D
4
4
4
4
6
1
6
1
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Sumitomo Tray 22
J-35616-4A (PU)
J-35616-42 (RD)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-5 (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-14 (GN)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-2A (GY)
J-35616-2A (GY)
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
Test Probe
Service
Terminal
Number
1500-0110
26365.213.011
26402.213.178
33001-1005
33012-1002
33093-0009
368083-1
54001801
54001802
7160-8234
7160-9786
7165-0342
7165-0385
7165-0851
8100-0457
8100-1427
8100-1429
8100-2922
8100-2923
8100-3420
8100-3421
8100-3456
8230-4492
8230-4502
Page 131
220 MT series sealed female

280 female
280 MDK 3 female sealed
150 MX female
150 MX female
220 MLC female
280 APEX male
280 APEX female
220 090 MT series cable seal - Blk.
220 MT series cable seal - Blk.
220 090 DL series cable seal - Brn.
220 090 DL series cable seal - Lt Gry.
.64 TS series cable seal - Dk. Grn.
220 TS series male sealed
220 DL series female sealed
220 DL series female sealed
.64 BS female
.64 BS female
.64 TS series female sealed
220 TS series male
220 SL series male
Description
15315247
12094429
12094429
J-38125-217
J-38125-217
12152110
15315247
12094429
12094429
N/A
N/A
N/A
N/A
N/A
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
15315247
Terminal
Removal
Tool
Insulation Crimp
7
7
J
7
K
J
A
6
7
H
7
K
J
E
E
E
2/E 2/E
E
E
E E
E
E
E
A/E A/E
E E
E E C
2
2
E
E
E
K
J
6
7
K
J
A
7
7
1 1 1 1
A A A
D D D
2
2 A/C A/C
C C C
2 2 A A
4
4
A
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Sumitomo Tray 26
J-35616-18 (BK)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-14 (GN)
J-35616-14 (GN)
J-35616-67 (YE)
J-35616-18 (BK)
J-35616-5 (PU)
J-35616-4A (PU)
N/A
N/A
N/A
N/A
N/A
J-35616-19 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-16 (L-GN)
J-35616-16 (L-GN)
J-35616-64B (L-BU)
J-35616-19 (BK)
J-35616-19 (BK)
Test Probe
Service
Terminal
Number
7114-4100-08
7114-4101-08
7114-4102-08
7114-4103-08
7114-4110-02
7114-4111-02
7114-4112-02
7114-4120-02
7114-4121-02
7114-4122-02
7114-4150-02
7114-4151-02
7114-4152-02
7116-4100-08
7116-4101-08
7116-4102-08
7116-4103-08
7116-4110-02
7116-4111-02
7116-4112-02
7116-4120-02
7116-4150-02
7116-4151-02
7116-4152-02
Page 132
150 YESC male

150 YESC male
150 YESC male sealed
280 YESC male
280 YESC male
280 YESC male
630 YESC male
630 YESC male
630 YESC male
150 YESC female
150 YESC female
150 YESC female sealed
280 YESC female
280 YESC female
280 YESC female
630 YESC female
Description
15315247
15315247
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
Terminal
Removal
Tool
Insulation Crimp
E
E
E
E
E
E
E
E
E
E
E
E
A
1
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 9
J-35616-3 (GY)
J-35616-3 (GY)
J-35616-3 (GY)
J-35616-3 (GY)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-2A (GY)
J-35616-2A (GY)
J-35616-2A (GY)
J-35616-2A (GY)
J-35616-4A (PU)
J-35616-35 (VT)
J-35616-35 (VT)
J-35616-42 (RD)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-35 (VT)
Test Probe
Service
Terminal
Number
7114-1470
7114-1475
7114-2875
7114-2876
7114-2877
7114-4020
7114-4021
7114-4022
7114-4140-02
7114-4141-02
7114-4142-02
7116-1470
7116-1473
7116-1474
7116-2875
7116-2876
7116-2877
7116-3250
7116-3251
7116-4121-02
7116-4122-02
7116-4140-02
7116-4141-02
7116-4142-02
Page 133
180 070 type male

180 S-type male
630 M-type male
630 M-type male
630 M-type male
220 090-II type male
180 Y-type female
180 070 type female
180 S-type female
630 M-type HD female
950 L-type female sealed
630 YESC female
630 YESC female
Description
15315247
15315247
12094430
12094430
12094430
15315247
15315247
15315247
12094430
12094430
12094430
15315247
15315247
15315247
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
12094430
Terminal
Removal
Tool
Insulation Crimp
E
E
E
E
E
E
E
E
F
F
F
G
G
G
G
C
C
C
C
C
C
C
C
G
3
3
3
3
3
3
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 10
J-35616-34 (YE)
J-35616-34 (YE)
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-43 (RD)
J-35616-33 (YE)
J-35616-33 (YE)
J-35616-33 (YE)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-22 (RD)
J-35616-22 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
Test Probe
Service
Terminal
Number
7114-1170
7114-1238
7114-1239
7114-4025
7114-4026
7114-4027
7114-4031
7114-4032
7114-6041
7114-6042
7116-1180
7116-1181
7116-1342
7116-1420
7116-4020
7116-4021
7116-4022
7116-4025
7116-4026
7116-4027
7116-4031
7116-4032
7116-6041
7116-6042
Page 134
220 090 type male

280 S-type male
280 S-type male
220 090-II type male sealed
480 187-type male
480 187-type male
800 312-type male
800 312-type male
220 090 type female
220 090 type female
280 S-type female
220 090-II female sealed
220 090-II female
220 090-II female
220 090-II female
480 187-type female
480 187-type female
800 312-type female
800 312-type female
Description
15315247
12094430
12094430
15315247
15315247
15315247
12094430
12094430
12094430
12094430
15315247
15315247
12094430
15315247
15315247
15315247
15315247
15313892
15313892
15313892
12094430
12094430
12094430
12094430
Terminal
Removal
Tool
Insulation Crimp
C/E C/E C
E
E
E
E
E
E
C/E C/E
E
E
4
A
4
A
A
A
4
A
A
A
A
A
A
1
C
C
A
A
1
C
B
B
B
B
F
B
B
B
F
B
G
B
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 11
J-35616-19 (BK)
J-35616-5 (PU)
J-35616-5 (PU)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-19 (BK)
J-35616-41 (BU)
J-35616-41 (BU)
J-35616-45 (YE)
J-35616-45 (YE)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-4A (PU)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-18 (BK)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-44 (YE)
J-35616-44 (YE)
Test Probe
Service
Terminal
Number
1 08 00 44452 2
2 21 24 47220 0
7114-1467-02
7114-1468-02
7114-1471
7114-1472
7114-1680-02
7116-1343
7116-1471
7116-1472
7116-1557-08
7116-1558-08
7116-1680-02
7116-1767-08
7116-1768-08
7116-2090
7116-2092
7116-2095
7116-2640-02
7116-2641-02
7116-2642-02
Page 135
280 SLK cable seal - Blu.

150 LKS round female sealed
100 RV-type male sealed
100 RV-type male sealed
180 SWP-type male sealed
180 SWP-type male sealed
130 S-type male sealed
280 S-type female
180 S-type female sealed
180 SWP-type female sealed
280 D-type female sealed
280 D-type female sealed
130 SSD-type female sealed
130 RV-type female sealed
130 RV-type female sealed
630 250 type female
630 250 type female
630 250 type female
630 250 type female
630 250 type female
630 250 type female
Description
N/A
J-38125-28
15315247
15315247
12094429
12094429
15315247
12094430
12094429
12094429
12094429
12094429
15315247
15315247
15315247
12094430
12094430
12094430
12094430
12094430
12094430
Terminal
Removal
Tool
Insulation Crimp
C
C
C
C
E
E
E
E
E
E
E
E
E
C
E
C
E
E
E
A
B
B
A
A
1
A
B
B
A
A
1
A
A
B
A
B
1
A
1
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 12
N/A
J-35616-66 (YE)
J-35616-17 (L-GN)
J-35616-17 (L-GN)
J-35616-34 (YE)
J-35616-34 (YE)
J-35616-13 (BU)
J-35616-4A (PU)
J-35616-33 (YE)
J-35616-33 (YE)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-12 (BU)
J-35616-12 (BU)
J-35616-12 (BU)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
Test Probe
Service
Terminal
Number
7157-3646
7157-3648
7157-3852
7157-3891
7157-3920-40
7157-3950-80
7157-3976-60
7157-3977-50
7157-7811-80
7157-7812
7157-7935
7158-3006-90
7158-3007-10
7158-3008-80
7158-3030-50
7158-3031-90
7158-3032-60
7158-3080-60
7158-3081-50
7158-3082-90
7158-3083
7158-3111-60
7158-3112-70
7158-3113-40
Page 136
220 cable seal - Gry.

220 090-II cable seal - Blk
480 cable seal - Blk.
280 cable seal - Blk. Brn.
100 cable seal - Org. Blk.
100 cable seal - Lt. Grn. Brn.
100 cable seal - Pink Brn.
180 SWP-type cable seal - Org. Brn.
180 SWP-type cable seal - Blk. Brn.
280 cable seal - Org. Blk.
220 cable seal - Blu.
220 cable seal - Brn.
150 YESC cable seal - Red
150 LKS cable seal - Blu.
150 YESC cavity plug - Grn.
630 YESC cavity plug - Grn.
630 YESC cable seal - Red
630 YESC cable seal - Blu.
630 YESC cable seal - Blk.
280 cable seal - Grn.
280 cable seal - Lt. Org.
280 cable seal - Wht.
Description
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Terminal
Removal
Tool
Insulation Crimp
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 13
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Test Probe
Service
Terminal
Number
7114-1050
7114-1257-02
7114-3250
7114-3251
7114-4036
7114-4037
7114-4060-02
7114-4231-08
7114-4720-02
7114-4721-02
7114-6046
7114-6047
7116-1257-02
7116-4035
7116-4036
7116-4037
7116-4060-02
7116-4231-08
7116-4720-02
7116-4721-02
7116-6046
7116-6047
SAIT-A03T-M064
SAITS-A03T-M064
Page 137
280 PA-type male

130 050-type male
950 L-type male
950 L-type male sealed
480 187 type male sealed
480 187 type male sealed
130 050-type male sealed
100 040-III type female
.64 YESC male
.64 YESC male
130 050-type female
480 187-type female
480 187-type female sealed
100 040-III type female
.64 YESC female
.64 YESC female
.64 AIT female
.64 AIT female sealed
Description
12094430
15315247
12094430
12094430
12094430
12094430
15315247
15315247
15315247
15315247
12094430
12094430
15315247
12094430
12094430
12094430
15315247
15315247
15315247
15315247
12094430
12094430
J-38125-215A
J-38125-215A
Terminal
Removal
Tool
Insulation Crimp
E
E
J
E
E
E
E
J
P
9
E
K
H
E
K
H
P
9
E
E
E
E
F
F
P
9
C
K
H
C
K
H
P
9
C
C
J
2
B
C
C
J
A
2
1
1
3
3
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 14
J-35616-5 (PU)
J-35616-13 (BU)
J-35616-21 (RD)
J-35616-21 (RD)
J-35616-41 (BU)
J-35616-41 (BU)
J-35616-13 (BU)
J-35616-16 (L-GN)
J-35616-65B (L-BU)
J-35616-65B (L-BU)
J-35616-45 (YE)
J-35616-45 (YE)
J-35616-12 (BU)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-40 (BU)
J-35616-12 (BU)
J-35616-16 (L-GN)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
J-35616-44 (YE)
J-35616-44 (YE)
J-35616-64B (L-BU)
J-35616-64B (L-BU)
Test Probe
Service
Terminal
Number
1-1411593-1
1393457-5
1393458-1
1411558-2
172749-2
173633-3
175266-5
1-962915-3
2 21 24 61420 0
2-1411578-2
4-964273-1
50420-8000
828904-1
828922-1
928999-5
962885-5
963143-1
963292-1
963293-1
964280-2
967056-1
967067-1
967067-2
Page 138
280 ELO female sealed

280 cavity plug - Wht.
280 ELO cable seal - Blu.
.64 ELO female
630 cavity plug - Gry.
180 Multi-Lock male
280 JPT male sealed
120 MLK female
.64 ELO female sealed
280 JPT female sealed
150 OBD female
280 JPT cable seal - Lt. Blu.
280 MCP cavity plug - Clr.
.64 MQS female
.64 MQS female sealed
.64 MQS cavity plug - Wht.
280 JPT cable seal - Yel.
280 JPT cable seal - Brn.
280 JPT female
.64 MQS cavity plug - Lt. Blu.
.64 MQS cable seal - Grn.
.64 MQS cable seal - Yel.
Description
15315247
N/A
N/A
12094429
N/A
15315247
15315247
J-38125-212
15381651-2
12094429
12093647
12094429
N/A
N/A
12094429
12094429
N/A
N/A
N/A
12093647
N/A
N/A
N/A
Terminal
Removal
Tool
Insulation Crimp
4
J
H
6
K
7
2
E
E
J
6
J
7
E
K
E
K
H
6
E
K
E
E
K
E
E
J
J
6
4
K
1
J
7
4
K
1
K
7
A
K
1
K
A
4
1
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 15
J-35616-4A (PU)
N/A
N/A
J-35616-64B (L-BU)
N/A
J-35616-34 (YE)
J-35616-16 (L-GN)
J-35616-5 (PU)
J-35616-16 (L-GN)
J-35616-64B (L-BU)
J-35616-4A (PU)
J-35616-2A (GY)
N/A
N/A
J-35616-64B (L-BU)
J-35616-64B (L-BU)
N/A
N/A
N/A
J-35616-4A (PU)
N/A
N/A
N/A
Test Probe
Service
Terminal
Number
1 08 00 44452 3
1062-12-0166
1062-16-0622
175091-1
2 21 24 47297 0
2 21 40 49206 0
7114-4618-02
7116-1050
7116-1261
7116-1531
7116-2033-02
7116-2951-02
7116-2952-02
7116-3252
7157-3580-60
7157-3791-60
7157-8767
7158-3114-90
7158-3116-50
7158-3374-90
7158-3503-50
7158-3504-80
7158-3505-40
SAIT-A03GF-M064
Page 139
280 SLK cable seal - Red

250 round female
150 round female
280 SLK female
280 SLK female sealed
.64 Kiazen male
280 PA-type female
100 120 SP-type female
220 E Type female sealed
630 250 type female
630 SEL 250 type female
630 SEL 250 type female
950 Y-type cable seal - Grn
280 E-Type cable seal - Grn.
220 090-II cavity plug - Blk.
280 cavity plug - Blu.
280 cable seal - Red
150 YESC cable seal - Blu.
.64 Kaizen cavity plug - Red Org.
.64 Kaizen cable seal - Brn.
.64 Kaizen cable seal - Grey
.64 AIT female
Description
N/A
J-38125-26
J-38125-27
15315247
15314260
12093647
J-38125-215A
12094430
12152110
15315247
12094430
12094430
12094430
12094430
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
J-38125-215A
Terminal
Removal
Tool
Insulation Crimp
P
E
K
P
E
E
C
A 4
4/C
A
4
P
A
K
5
1
D
5
.35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0 .35 .50 .75 .80 1.0 1.5 2.0 2.5 3.0 4.0 5.0
Core Crimp
CRIMPING MATRIX
Yazaki Tray 27
N/A
J-35616-37 (L-BU)
J-35616-66 (YE)
J-35616-40 (BU)
J-35616-4A (PU)
J-35616-4A (PU)
J-35616-65B (L-BU)
J-35616-4A (PU)
J-35616-16 (L-GN)
J-35616-18 (BK)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-42 (RD)
J-35616-22 (RD)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
J-35616-64B (L-BU)
Test Probe
TO ORDER CALL
1-800-GMTOOLS (800-468-6657)
J-38125-620H
$14.95 US
Revised 11/07

J 38125 620H

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TABLE OF CONTENTS

ITEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE NUMBER

TERMINALS & CONNECTORS

Another term for a bulk length of wire.

The molded plastic part which houses one or

Connector Position Assurance

A lock designed to retain connectors when mated.

Conductive portion of a wire, covered with insulation

Crimp & Seal Splice Sleeve

A crimp only splice with an integral heat shrink shield

Another term for a cut length of wire.

Removal tool for terminal, TPA, CPA or opening of

Terminated wires housed in a connector intended to be

Provides terminal retention in addition to lock tang,

Formed metal attached to the end of the wire that

Terminal Lock Tangs

Flexible portion of the terminal that locks terminal into

Terminal Position Assurance

A loose piece component that snaps on to a connector.

Portion of terminal that is used for attachment to wire.

Connector Position Assurance lock

Terminal Position Assurance lock

Weather Pack, a family of sealed connection systems utilizing a pin and

Acknowledgement: Technical Information provided courtesy of John Roberts

TERMINAL REMOVAL INSTRUCTIONS

STANDARD TERMINAL REPLACEMENT

STRIP INSULATION APPROPRIATE TO THE

POSITION WIRE IN TERMINAL AS SHOWN.

HAND CRIMP CORE WINGS FIRST, THEN

TERMINAL REPLACEMENT SEALED

CUT OFF TERMINAL BETWEEN CORE AND

APPLY CORRECT SEAL PER GAUGE SIZE OF

POSITION STRIP AND SEAL IN TERMINAL AS

HAND CRIMP CORE WINGS FIRST, THEN

TERMINAL CRIMP TOOL

TERMINAL CRIMP TOOL

6. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY RELEASES.

SPLICE CRIMP TOOL

1. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY OPENS.

6. REPEAT STEPS 3, 4 AND 5.

TERMINAL WITH SEAL APPLICATION

CRIMP AND SEAL APPLICATION

GLUED HEAT SHRINK APPLICATION

CUT OFF CLIP. STRIP INSULATION (1/2 LENGTH).

PREFERRED: LOCATE NEW SPLICE 40 MM

DURASEAL CRIMP SPLICE SLEEVE

Yellow 12-10 AWH PN 12089191

Blue 16-14 AWG PN 12089190

Salmon 20-18 AWG PN 12089189

Green 24-22 AWG PN 88988379

CRIMP AND SEAL SPLICE SLEEVE

CUT OFF CLIP IF APPLICABLE. STRIP

PREFERRED: LOCATE NEW SPLICE 40 MM

HAND CRIMP USING CRIMPING TOOL J-38125-8.

APPLY HEAT USING ULTRATORCH OR OTHER

IN SOME EXTREME HIGH TEMPERATURE

SEALED SPLICE CRIMP MATRIX

Splice clip P/N

Recommended area in crimp

2.80 - 5.50 mm2

5.50 - 8.90 mm2

2.16 - 3.29 mm2