Content .. 30 31 32 33 ..

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 32

HOME

click (latch), press on one side of the connector until that

latch engages, then press on the opposite side to

engage the other latch.

NOTES

●

Deutsch connectors are colored coded for location pur-

poses. Those connectors associated with left side

accessories, such as the front and rear left turn signals,

Figure B-6. Deutsch Connector Pick Tool

are gray. All other connectors, including those associ-

(Part No. HD-41475-100)

ated with right side accessories, are black.

●

If it should become necessary to replace a plug or

Gently depress terminal latches inside pin housing and

receptacle, please note that the 8-place and 12-place

back out pins th

gray and black connectors are not interchangeable.

Since location of the alignment tabs differ between the

NOTE

black and gray connectors, plugs or receptacles must be

If new terminals must be installed, see CRIMPING

replaced by those of the same color. If replacing both the

INSTRUCTIONS on this page.

socket and pin halves, then the black may be substituted

for the gray, and vice versa. The socket and pin halves of

Fit wire seal into back of pin housing. Grasp crimped pin

all other connectors are interchangeable, that is, the

approximately 1 inch (25.4 mm) behind the contact bar-

black may be mated with the gray, since the alignment

rel. Gently push pins through holes in wire seal into their

tabs are absent and the orientation of the external latch

respective numbered locations. Feed pin into chamber

is the same.

until it “clicks” in place. Verify that pin will not back out of

chamber; a slight tug on the wire will confirm that it is

Fit the attachment clip to the pin housing, if removed.

properly locked in place.

Place large end of slot on attachment clip over T-stud on

Insert tapered end of secondary locking wedge into pin

frame. Push assembly forward to engage small end of

housing and press down until it snaps in place. The

slot.

wedge fits in the center groove within the pin housing

and holds the terminal latches tightly closed.

NOTE

CRIMPING INSTRUCTIONS

While rectangular wedges do not require a special orienta-

tion, the conical secondary locking wedge of the 3-place con-

Use the Deutsch Terminal Crimp Tool (HD-39965) to install

nector must be installed with the arrow pointing toward the

standard size terminals with crimp tails, as described under

external latch. See Figure B-4.

STANDARD TERMINALS below. To install the mini-Deutsch

NOTE

terminals with crimp tails, see MINI TERMINALS, which fol-

lows. To install those terminals without crimp tails, both stan-

If the secondary locking wedge does not slide into the

dard and mini-Deutsch, use the Deutsch Solid Barrel Contact

installed position easily, verify that all terminals are fully

Crimp Tool (HD-42879) as described under SOLID BARREL

installed in the pin housing. The lock indicates when termi-

CONTACTS.

nals are not properly installed by not entering its fully

installed position.

NOTE

A Deutsch Connector Service Kit (HD-41475) contains a

selection of wire seals, internal seals, seal plugs, secondary

ASSEMBLING/INSTALLING

locking wedges, attachment clips and socket/pin terminals.

Also included is a compartmented storage box, carrying case

Insert socket housing into pin housing until it snaps in

and pick tool (HD-41475-100) used for the removal of all

place. Two-, three-, four- and six-place Deutsch connec-

types of locking wedges.

tors have one external latch on the socket half of the

connector. To fit the halves of the connector together, the

latch on the socket side must be aligned with the latch

STANDARD TERMINALS

cover on the pin side.

For those connectors with two external latches (8-place

Obtain the DEUTSCH TERMINAL CRIMP TOOL (HD-

and 12-place), a different system is used to prevent

39965).

improper assembly. Align the tabs on the socket housing

Squeeze the handles to cycle the crimp tool to the fully

with the grooves on the pin housing. Push the connector

open position. See Figure B-7.

halves together until the latches “click.” If latches do not

B-4

Appendix B

HOME

f1516x8x

Gauge

Nest of

Wire

Crimp Tool

Front

16-18

Middle

Locking

Bar

1. Insert contact through hole of locking bar

2. Insert stripped lead until it contacts

so that barrel rests on nest of crimp tool.

locking bar.

3. Close and squeeze crimp tool.

4. Raise locking bar and remove contact.

Insulation crimp

Core crimp

5. Inspect quality of core and insulation crimps.

f1558x8x

Figure B-7. Deutsch Crimping Procedure

Appendix B B-5

HOME

Raise the locking bar by pushing up on bottom flange.

SOLID BARREL CONTACTS

With the crimp tails facing upward, insert contact

(socket/pin) through hole of locking bar, so that the

For Size 20, 16 and 12 Contacts

rounded side of the contact barrel rests on the nest (con-

Wire Range 26-12 AWG

cave split level area) of the crimp tool. Use the middle

hole in the locking bar for 16-18 gauge wire, the front

Obtain the DEUTSCH SOLID BARREL CONTACT

hole for 20 gauge wire.

CRIMP TOOL (HD-42879).

Release locking bar to lock position of contact. If the

Squeeze the handles to cycle the crimp tool to the fully

crimp tails are slightly out of vertical alignment, the crimp

open position.

tool automatically rotates the contact so that the tails

face straight upward. When correctly positioned, the

Remove locking pin from selector knob. See Figure B-8.

locking bar fits snugly in the space between the contact

band and the core crimp tails.

Raise selector knob and rotate until selected wire size

stamped on wheel is aligned with “SEL. NO.” arrow. See

Strip lead removing 5/32 inch (4.0 mm) of insulation.

upper frame of Figure B-9.

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that

Loosen knurled locknut and turn adjusting screw clock-

short pair of crimp tails squeeze bare wire strands, while

wise (in) until it stops.

long pair folds over insulation material.

Turn tool over and drop contact into indentor cover hole

Squeeze handle of crimp tool until tightly closed. Tool

with the wire end out.

automatically opens when the crimping sequence is

complete. Raise up locking bar and remove contact.

Turn adjusting screw counterclockwise (out) until contact

Inspect the quality of the core and insulation crimps. Dis-

is flush with bottom of depression in indentor cover.

tortion should be minimal.

Tighten knurled locknut.

Slowly squeeze handles of crimp tool until contact is

centered between indentor points. See middle frame of

Figure B-9.

MINI TERMINALS

Strip wire lead removing 1/4 inch (6.4 mm) of insulation.

Obtain the PACKARD TERMINAL CRIMP TOOL (HD-

10.

Insert bare wire strands into contact barrel. See lower

38125-7).

frame of Figure B-9.

Strip wire lead removing 5/32 inch (4.0 mm) of insula-

tion.

11.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

Compress handles until ratchet automatically opens.

complete.

NOTE

12.

Remove crimped contact from indentor.

Always perform core crimp before insulation crimp.

13.

Inspect the quality of the crimp. Verify that all wire

Position the core crimp on nest E of the crimping tool. Be

strands are in crimp barrel.

sure the core crimp tails are facing the forming jaws.

Gently apply pressure to handles of tool until crimpers

just secure the core crimp tails.

Insert stripped wire between crimp tails. Verify that wire

Adjusting

is positioned so that short pair of crimp tails squeeze

Locking

Screw

bare wire strands, while long pair is positioned over the

insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete.

Position the insulation crimp on nest C of the crimping

tool. Be sure the insulation crimp tails are facing the

forming jaws.

Selector

Squeeze handle of crimp tool until tightly closed. Tool

Locknut

f1535x8x

Knob

automatically opens when the crimping sequence is

complete.

Figure B-8. Deutsch Solid Barrel Contact Crimp Tool

10.

Inspect the quality of the core and insulation crimps. Dis-

(Part No. HD-42879)

tortion should be minimal.

B-6

Appendix B

HOME

NOTE

Rotate selector knob to align wire size on wheel

with arrow stamped in tool.

Tool must be readjusted when changing contact size/type.

14. Install pin to lock position of selector knob.

Selector

Knob

f1534x8x

Turn adjusting screw as described in text. When

contact is flush with bottom of depression in

indentor cover, squeeze handles to center contact

between indentor points.

Indentor

Cover

Contact

Indentor

Points

f1532x8x

Insert bare wire strands into contact barrel.

Squeeze handle of crimp tool until tightly closed.

f1533x8x

Figure B-9. Deutsch Solid Barrel Contact

Crimping Procedure

Appendix B B-7

HOME

MULTILOCK ELECTRICAL CONNECTORS

B.2

is engaged but then inadvertently released. Repeat the

REMOVING SOCKET/PIN

step without releasing the tang.

TERMINALS

NOTE

Remove connector from the retaining device, either

An Electrical Terminal Crimp Tool (Part No. HD-41609) is

attachment or rosebud clip.

used to install Multilock pin and socket terminals on wires. If

new terminals must be installed, see CRIMPING INSTRUC-

Depress the button on the socket terminal side of the

TIONS in this section.

connector

(plug) and pull apart the pin and socket

halves. See Figure B-10.

Bend back the latch slightly and free one side of second-

INSTALLING SOCKET/PIN

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

TERMINALS

terminals in chambers of connector housing.

Looking in the terminal side of the connector (opposite

NOTE

the secondary lock), take note of the cavity next to each

For wire location purposes, numbers are stamped into the

terminal.

secondary locks of both the socket and pin housings. See

See Figure B-11. With the flat edge against the terminal,

Figure B-13.

insert the pick (Snap-On TT600-3) into the cavity until it

stops. Pivot the end of the pick away from the terminal

From the secondary lock side of the connector, insert the

and gently tug on wire to pull terminal from chamber. Do

terminal into its respective numbered chamber until it

not tug on the wire until the tang is released or the termi-

snaps in place. For proper fit, the slot in the terminal

nal will be difficult to remove. A “click” is heard if the tang

must face the tang in the chamber.

Secondary Lock

NOTE

Open

For exploded views of

place and 6-place Multilock

connectors, see Figure B-

Pin Terminal

14.

Button

Secondary Lock

Latch

Open

Latch

Pin Housing

Socket Housing

Socket Terminal

Latch

Secondary Lock

f1292x2x

Open

Figure B-10. 10-Place Multilock Connector (Exploded View)

B-8

Appendix B

HOME

Secondary Lock

Open

f1289x2x

Socket Terminal

Socket Housing

Pick Tool

Pin Terminal

Secondary Lock

Open

Pick Tool

Pin Housing

1. Open Secondary Lock.

2. Insert Pick into Cavity on Mating End of Connector.

3. Pivot End of Pick to Release Tang.

4. Gently Tug on Wire to Remove Terminal from Housing.

Figure B-11. Release Tang and Back Out Terminals

NOTE

The tang in the chamber engages the slot to lock the terminal

Pin Housing

Tang

Button

in position. On the pin side of the connector, tangs are posi-

tioned at the bottom of each chamber, so the slot in the pin

terminal (on the side opposite the crimp tails) must face

downward. On the socket side, tangs are at the top of each

chamber, so the socket terminal slot (on the same side as the

crimp tails) must face upward. Up and down can be deter-

mined by the position of the release button (used to separate

the pin and socket halves), the button always being the top of

the connector. See Figure B-12.

Gently tug on wire end to verify that the terminal is

Tang

Socket Housing

f1428x8x

locked in place and will not back out of chamber.

Figure B-12. Tang Location (Cross Sectional View)

Appendix B B-9

HOME

f1287x2x

Secondary Locks Open

- AMP

3-Place Connector

6-Place Connector

10-Place Connector

Figure B-13. Numbers Stamped on Secondary Locks for Wire Color Locations (Socket Housings Shown)

f1291x2x

3-Place Connector

6-Place Connector

Socket Side

Socket Terminal

Secondary Lock (Open)

Latch

Socket Housing

Button

Pin Side

Pin housing

Latch

Secondary Lock (Open)

Pin Terminal

f1288x2x

Figure B-14. 3-Place and 6-Place Multilock Connectors

B-10

Appendix B

HOME

f1286x2x

Locking Bar

Insulation

Core

Groove

Crimp Tail

Insulation

Crimp Tail

Core

Locking Bar

Crimp Tail

Groove

Tang Slot

PIN TERMINAL

Tang Slot

SOCKET TERMINAL

f1290a2x

Locking

Bar

1. Raise locking bar and seat contact on nest

2. Insert stripped lead until it contacts

of crimp tool. Release locking bar.

locking bar.

Gauge

Nest of

Wire

Crimp Tool

Front

Middle

Rear

3. Close and squeeze crimp tool.

4. Raise locking bar and remove contact.

Figure B-15. Multilock Crimping Procedure

Appendix B B-11

HOME

Rotate the hinged secondary lock inward until tabs fully

CRIMPING INSTRUCTIONS

engage latches on both sides of connector.

Insert the socket housing (plug) into the pin housing

Squeeze the handles to cycle the crimp tool (Part No.

(receptacle) unt

HD-41609) to the fully open position.

Install connector on retaining device, either attachment

Raise locking bar by pushing up on bottom flange. With

or rosebud clip.

the crimp tails facing upward, insert contact (socket/pin)

through locking bar, so that the closed side of the con-

tact rests on the nest (concave split level area) of the

crimp tool). Use the front nest for 20 gauge wire, the

middle for 16 gauge and the rear for 18 gauge. See Fig-

ure B-15.

Release locking bar to lock position of contact. When

correctly positioned, the locking bar fits snugly in the

space at the front of the core crimp tails.

Strip lead removing 5/32 inch (4.0 mm) of insulation.

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that

short pair of crimp tails squeeze bare wire strands, while

long pair folds over insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete. Raise up locking bar and remove contact.

Inspect the quality of the core and insulation crimps. Dis-

tortion should be minimal.

B-12

Appendix B

HOME

DELPHI ELECTRICAL CONNECTORS

B.3

GENERAL

Use these instructions to service the following connectors:

● Ignition Coil [83B]

● Front Fuel Injector [84B]

● Rear Fuel Injector [85B]

● IAC [87B]

● TP Sensor [88B]

9297

● IAT Sensor [89B]

Figure B-16. Remove Wire Lock

● ET Sensor [90B]

● Oil Pressure Sender [139B]

● Security Siren [142B]

REMOVING SOCKET TERMINALS

NOTE

Although the parts of the different Delphi connectors vary in

9302

appearance, the instructions which follow will work for all.

The only exception is the oil pressure sender connector

Figure B-17. Remove Terminal Lock

[139B], the terminals of which are removed like the Packard

push-to-seat connectors. Therefore, see Section B.4 PACK-

ARD ELECTRICAL CONNECTORS,

150 METRI-PACK

SERIES, to remove/install terminals in this connector.

Bend back the external latch(es) slightly and separate

pin and socket halves of connector.

If present, free one side of wire lock from ear on wire end

of socket housing, then release the other side. Release

wires from channels in wire lock and remove from socket

housing. See Figure B-16.

9301

Use a fingernail to pry colored terminal lock loose and

then remove from mating end of socket housing. See

Figure B-18. Gently Pry Away Tang

Figure B-17.

Using a thin flat blade, like the unsharpened edge on an

X-Acto knife, gently pry tang outward away from termi-

nal, and then tug on wire to back terminal out wire end of

Gently push tang on socket housing inward toward

chamber. Do not pull on wire until tang is released or ter-

chamber. With the open side of the terminal facing the

minal will be difficult to remove. See Figure B-18.

tang, push terminal into chamber at wire end of socket

housing.

INSTALLING SOCKET TERMINALS

Gently tug on wire to verify that terminal is locked and

will not back out of chamber. If necessary, use fingernail

to push tang into engagement with terminal.

NOTE

Install colored terminal lock onto mating end of socket

For wire location purposes, alpha or numeric characters are

housing. See Figure B-17.

stamped into the wire end of each socket housing.

Appendix B B-13

HOME

If present, seat wires in separate channels of wire lock

Push pin and socket halves of connector together until

and then push channels inside chambers at wire end of

external latch(es) engage.

socket housing. Fully installed, slot on each side of wire

lock engages ear on socket housing. See Figure B-16.

B-14

Appendix B

HOME

PACKARD ELECTRICAL CONNECTORS

B.4

If necessary, crimp new terminals on wires. See Crimp-

150 METRI-PACK SERIES

ing Instructions at the end of this section.

General

Assembly

Use these instructions to service the following connectors:

NOTE

● Cruise Control Module [17B]

For wire location purposes, alpha characters are stamped

● MAP Sensor [80B]

into the socket housings.

● Fuel Level Sender/Fuel Pump [141B]

Using a thin flat blade, like that on an X-Acto knife, care-

fully bend the tang outward away from the terminal body.

See D in Figure B-19 or Figure B-20.

Gently pull or push on the lead to install the terminal

Disassembly

back into the chamber. A click is heard when the termi-

nal is properly seated.

Bend back the external latch slightly and separate the

pin and socket halves of the connector.

Gently pull or push on the lead to verify that the terminal

is locked in place.

Note that there are two types of connectors in this

On push-to-seat type connectors, seat wires in separate

series, pull-to-seat terminal and push-to-seat terminal

connectors. Remove wire lock from wire end of socket

channels of wire lock and then push channels inside

housing on push-to-seat type connectors. For best

chambers at wire end of socket housing. Fully installed,

slot on each side of wire lock engages ear on socket

results, free one side of wire lock first and then release

the other side. See A of Figure B-20.

housing. See A of Figure B-20.

Connect the pin and socket halves of the connector.

Look into the mating end of the connector to find the

locking tang. The tangs are always positioned in the mid-

dle of the chamber and are on the same side as the

external latch.

280 METRI-PACK SERIES

Gently insert the point of a one inch safety pin into the

chamber about 1/8 inch (3.2 mm) staying between the

terminal and the chamber wall, and then pivot the end of

General

the pin toward the terminal body. See B in Figure B-19 or

Figure B-20. On push-to-seat type connectors, take note

Use these instructions to service the following:

that there is a small opening for insertion of the pin.

● System Fuse Block [64B]

If a click is heard, remove the pin and repeat the proce-

dure. The click is the sound of the tang returning to the

System Fuse Block

locked position as it slips from the point of the pin. Pick

at the tang in this manner until the clicking stops and the

Disassembly

pin seems to slide in at a slightly greater depth than it

Remove system fuses and relay(s) from fuse block. See

had previously. This is an indication that the tang has

Section

8.3 SYSTEM FUSES, SYSTEM FUSES/

been depressed.

RELAYS, REMOVAL.

NOTE

Remove secondary locks as follows:

On those terminals that have been extracted on multiple

a. Insert end of small flat blade screwdriver under lip of

occasions, no clicking sound may be heard when the pin is

locking wedge and gently pry up secondary lock.

pivoted to depress the tang, but proceed as if the clicking is

NOTE

audible.

For best results, start with locking wedge on outboard side of

Remove the pin. On pull-to-seat connectors, push on the

secondary lock. See Figure B-21.

lead to extract the terminal from the mating end of the

connector. See C in Figure B-19. On push-to-seat con-

Remove socket terminals as follows:

nectors, pull on the lead to draw the terminal out the wire

a. Looking into chamber at top of fuse block, note the

end. See C in Figure B-20.

tang next to each socket terminal.

Appendix B B-15

HOME

f2400x8x

Locate tang on latch side of chamber.

Push on wire end of lead to remove terminal.

Pivot end of pin to depress tang.

Raise tang and re-install terminal.

Figure B-19. Depress Tang and Extract Terminal From Mating End of Pull-to-Seat Connector

f2401x8x

Remove wire lock from wire end of connector.

Pull on wire end of lead to remove terminal.

Pivot end of pin to depress tang.

Raise tang and re-install terminal.

Figure B-20. Depress Tang and Extract Terminal From Wire End of Push-to-Seat Connector

B-16

Appendix B

HOME

b. Using a thin flat blade, like that on an X-Acto knife,

a. With the open side of the socket terminal facing the

gently push tang away from terminal, and then tug

tang, push lead into chamber at the wire end of the

on wire to back terminal out wire end of chamber.

fuse block. A click is heard when the terminal is

properly engaged.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

b. Gently tug on the wire to verify that the terminal is

locked in place and will not back out of the chamber.

Assembly

Install secondary locks as follows:

Install socket terminals as follows:

a. With the locking wedges positioned above the tangs

in each chamber, slide flat side of secondary lock

NOTE

into slot (between rows), and push down until it bot-

See Section B.8 WIRING DIAGRAMS, MAIN HARNESS, for

toms. See Figure B-21.

wire colors and locations.

Install system fuses and relay(s) in fuse block. See Sec-

tion 8.3 SYSTEM FUSES, SYSTEM FUSES/RELAYS,

INSTALLATION.

480 METRI-PACK SERIES

General

Use these instructions to service the following connector:

● B+ [160]

Lip of

Locking Wedge

f2205x8x

Disassembly

Figure B-21. Remove Secondary Locks From Fuse Block

Remove seat. See Section 2.25 SEAT, REMOVAL.

1WARNING

Disconnect negative (-) battery cable first. If positive (+)

cable should contact ground with negative (-) cable con-

nected, the resulting sparks can cause a battery explo-

sion, which could result in death or serious injury.

(00049a)

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

Unthread bolt and remove battery positive cable (red)

from battery positive (+) terminal.

f2204x8x

Using a T40 TORX drive head, loosen bolt to move lip of

hold-down clamp off edge of battery. Remove battery

from battery box.

Headlamp

Ignition

Radio Power

Cut anchored cable strap to release accessory connec-

Lighting

Accessory

tor and B+ connector from left side of frame crossmem-

Instruments

Battery

ber (in front of battery box). See Figure B-23.

Brakes/Cruise

10. Brake Light Relay

Radio Memory

11. P&A

Using small flat blade screwdriver, depress button on pin

housing (red wire) side of the connector and pull apart

Figure B-22. Fuse Block (FLHX, FLHTC/U, FLTR)

the pin and socket halves. See A of Figure B-24.

Appendix B B-17

HOME

Mate pin and socket halves of connector.

Install new anchored cable strap in lower hole on left

side of frame crossmember (in front of battery box).

Tighten cable strap to capture conduit of both accessory

connector and B+ connector approximately one inch

from connector housings. See Figure B-23.

Place battery in battery box, terminal side forward.

1WARNING

Connect positive (+) battery cable first. If positive (+)

cable should contact ground with negative (-) cable con-

nected, the resulting sparks can cause a battery explo-

sion, which could result in death or serious injury.

(00068a)

B+ Connector

f2427x8x

Figure B-23. Remove Seat

Bend back the latch slightly and free one side of second-

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

terminal in chamber of connector housing. See B of Fig-

ure B-24.

On the mating end of the connector, note the tang in the

f2258x8x

square shaped opening centered next to the terminal.

Gently insert the point of a stick pin or large safety pin

into the opening between the tang and the chamber wall

until it stops. Pivot the end of the pin toward the terminal

body to depress the tang. Remove the pin and then pull

terminal out wire end of connector housing. See C of

Figure B-24.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

f2259x8x

Assembly

Carefully bend the tang outward away from the terminal

body.

With the tang on the same side as the square shaped

opening in the mating end of the connector housing,

feed terminal into wire end of connector housing until it

“clicks” in place.

Verify that terminal will not back out of the chamber. A

slight tug on the cable will confirm that it is locked.

f2260x8x

Rotate the hinged secondary lock inward until latches

fully engage tabs on both sides of connector housing.

Figure B-24. Remove Socket Terminal

B-18

Appendix B

HOME

Insert bolt through battery positive cable

(red) into

Using a thin flat blade, like that on an X-Acto knife, care-

threaded hole of battery positive (+) terminal. Tighten

fully bend the tang outward away from the terminal body.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

With the tang facing the chamber wall, push the lead into

Insert bolt through battery negative cable (black) into

the chamber at the wire end of the connector. A click is

threaded hole of battery negative (-) terminal. Tighten

heard when the terminal is properly seated.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

Gently tug on the wire end to verify that the terminal is

10. Rotate hold-down clamp so that the lip (with rubber pad)

locked in place and will not back out of the chamber.

rests on the edge of the battery. Using a T40 TORX drive

Rotate the hinged secondary lock inward until tabs fully

head, tighten the clamp bolt to 15-20 ft-lbs (20-27 Nm).

engage latches on both sides of connector.

11. Install seat. See Section 2.25 SEAT, INSTALLATION.

Push the pin and socket halves of the connector

together until the latches “click.”

Install connector on barbed anchor or other retaining

device, if present.

630 METRI-PACK SERIES

General

800 METRI-PACK SERIES

Use these instructions to service the following connector:

● Main to Interconnect Harness [15]

General

Use these instructions to service the following:

Disassembly

● Maxi-Fuse Holder [5]

Remove connector from barbed anchor or other retain-

ing device, if present.

Disassembly

Bend back the external latch slightly and separate pin

and socket halves of the connector.

Remove maxi-fuse. See Section 8.3 SYSTEM FUSES.

Bend back the latch slightly and free one side of the sec-

MAXI-FUSE, REMOVAL.

ondary lock. Repeat the step to unlatch the other side.

Remove socket terminals as follows:

Rotate the secondary lock outward on hinge to view the

a. Gently pull socket housing to disengage slots from

terminals in the chambers of the connector housing. The

tabs on socket housing. See A of Figure B-25. Free

locking tang is on the side opposite the crimp tails and

secondary lock from cables and set aside.

engages a rib in the chamber wall to lock the terminal in

place.

b. Take note of the opening on one side of the socket

terminal. Gently insert flat blade of pick (Snap-On

Moving to the mating end of the connector, take note of

TT600-5) or small screwdriver into opening until it

the small opening on the chamber wall side of each ter-

stops. Pivot the pick toward the terminal body and

minal.

hold in position. See B of Figure B-25.

Insert pick

(Snap-on® TT600-3) into opening until it

c. Tug on cable to pull socket from wire end of socket

stops. Pivot the end of the pick toward the terminal to

housing. A firm tug is necessary to overcome the

depress the locking tang.

resistance of the rubber seal.

Remove the pick and gently tug on the wire to pull the

d. Repeat steps 2(b) and 2(c) to remove remaining

terminal from the wire end of the connector. Repeat

socket terminal.

steps if the terminal is still locked in place.

If necessary, crimp new terminals on wires. See Crimp-

ing Instructions at the end of this section.

Assembly

Install socket terminals as follows:

NOTE

For wire location purposes, alpha characters are molded into

a. Carefully bend tang outward away from the terminal

the secondary locks of each connector housing.

body. See C of Figure B-25.

Appendix B B-19

HOME

e. Install secondary lock onto cables and then push

f2245x8x

onto wire end of socket housing until slots engage

tabs on sides of socket housing.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES.

MAXI-FUSE, INSTALLATION.

Tab

PACKARD MICRO 64

Secondary

Lock

General

Use these instructions to service the following connectors:

f2244x8x

● Speedometer [39]

● Tachometer [108]

Disassembly

Bend back the external latches slightly and separate the

pin and socket halves of the connector.

NOTE

To differentiate between the speedometer and tachometer

connectors, note that the speedometer connector has a sec-

ond length of conduit leading to the odometer reset switch.

Locate the head of the secondary lockpin on one side of

the connector housing. See Figure B-27.

Insert the blade of a small screwdriver between the cen-

ter ear of the lockpin and the connector housing and

gently pry out lockpin. When partially removed, pull lock-

pin from connector housing.

Obtain the Packard Micro 64 Terminal Remover (HD-

45928). See Figure B-26. Proceed as follows:

a. Locate small hole between terminals on mating end

f2246x8x

of connector. See Figure B-27.

Figure B-25. Remove Socket Terminals

b. Feed socket into wire end of socket housing until it

“clicks” in place. Verify that socket will not back out

of chamber. A slight tug on the cable will confirm

that it is locked.

c. Push rubber seal into wire end of socket housing.

d. Repeat steps

1(a) thru

1(c) to install remaining

Figure B-26. Packard Micro 64 Terminal Remover

socket terminal.

(Part No. HD-45928).

B-20

Appendix B

HOME

Assembly

Small

f2202x8x

Hole

Insert terminal into its respective numbered chamber on

wire end of connector. No special orientation of the ter-

Secondary

Lockpin

minal is necessary.

NOTE

For wire location purposes, the corners of the socket housing

are stamped with the numbers 1, 6, 7 and 12, representing

terminals 1-6 on one side, and 7-12 on the other. See Figure

B-27.

Bottom the terminal in the chamber and then gently tug

on the wire to verify that it is locked in place.

Figure B-27. Mating End of Connector

NOTE

Once the terminal is removed it may not lock in place when

first reinstalled. Until the lock engages, move the terminal

back and forth slightly while wiggling the lead.

Since the terminal remover tool releases two terminals

simultaneously, repeat step 2 on the adjacent terminal

even if it was not pulled from the connector housing.

With the center ear on the head of the secondary lockpin

facing the mating end of the connector, push lockpin in

until head is flush with the connector housing.

Push the pin and socket halves of the connector

f2196x8x

together until the latches “click.”

Crimping Instructions

Strip lead removing 1/8 inch (3.0 mm) of insulation.

Obtain the Packard Micro 64 Terminal Crimper (HD-

45929). See Figure B-29.

Squeeze the handles to cycle the tool to the fully open

position.

Obtain new contact (socket terminal). Verify that contact

and crimp tails are not bent or deformed.

f2197x8x

Raise locking bar and barrel holder by pushing up on

bottom tab with index finger. See Figure B-30.

Figure B-28. Insert Tool and Remove Terminal

b. Push the adjacent terminals all the way into the con-

nector housing and then insert tool into hole until it

bottoms. See upper frame of Figure B-28.

c. Leaving the tool installed, gently tug on wires to pull

either one or both terminals from wire end of con-

nector. See lower frame of Figure B-28. Remove

tool.

If necessary, crimp new terminals on wires. See Crimp-

Figure B-29. Packard Micro 64 Terminal Crimper

ing Instructions on this page.

(Part No. HD-45929)

Appendix B B-21

HOME

Insert wires between crimp tails until ends make contact

with locking bar. Verify that wire is positioned so that

wide pair of crimp tails squeeze bare wire strands, while

the narrow pair folds over the insulation material.

Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is

complete. See Figure B-32.

10. Raise locking bar and barrel holder to remove contact.

11. Inspect the quality of the core and insulation crimps. Dis-

tortion should be minimal.

f2198x8x

Figure B-30. Raise Locking Bar and Barrel Holder

PACKARD 100W

f2199x8x

General

Use these instructions to service the following connector:

● ECM [78]

Disassembly

Gently depress latch on each side of the clear plastic

Locking

Barrel

secondary lock and remove. For best results, release

Bar

Holder

one side at a time, See Figure B-33.

Figure B-31. Position Contact in Crimper

f2062x8x

f2201x8x

Figure B-32. Crimp Terminal Onto Wire

With the crimp tails facing upward, insert contact

through locking bar into front hole in barrel holder (20-22

gauge wire).

Latch

Release locking bar to lock position of contact. When

Rib

Conduit

correctly positioned, the locking bar fits snugly in the

Secondary Lock

Cable Strap

space at the front of the core crimp tails and the closed

Strain Relief Collar

External Latch

side of the terminal rests on the outer nest of the crimp

tool. See Figure B-31.

Figure B-33. Remove Secondary Lock

B-22

Appendix B

HOME

Exercising caution to avoid pinching wires, press halves

of socket housing together until three plastic pins fully

engage slots in housing. See Figure B-34.

Install new cable strap in groove of strain relief collar

capturing cable conduit. See Figure B-33.

With the two ribs on the secondary lock on the same

Pins

side as the external latch, install over terminals until

latches lock in place.

Crimping Instructions

Strip wire lead removing 5/32 inch (4.0 mm) of insula-

tion.

f2063x8x

Compress handles until ratchet automatically opens.

NOTE

Figure B-34. Separate Halves of Socket Housing

Always perform core crimp before insulation/seal crimp.

See Figure B-36. Determine the correct die or nest for

the core crimp.

Position the core crimp on the appropriate nest. Be sure

the core crimp tails are facing the forming jaws.

Packard Terminal Crimp Dies (Nests)

Packard 270

Packard 271

Packard 115

(HD-38125-6)

(HD-38125-7)

(HD-38125-8)

f2064x8x

Figure B-35. Push Wire to Extract Terminal

Carefully cut cable strap to free strain relief collar from

conduit.

Using a thin blade, gently pry at seam at back of socket

housing to release three plastic pins from slots in hous-

ing. Separate and spread halves of socket housing. See

Figure B-34.

Push on selected wire to free terminal from chamber.

Sealed

Non-Sealed

See Figure B-35.

Terminals

If necessary, crimp new terminals on wires. See Crimp-

1-5

A-E

F-G

ing Instructions on the next page.

Butt Splices*

Assembly

*See Appendix B.6 SEALED BUTT SPLICE CONNECTORS.

From inside socket housing, gently pull on wire to draw

Figure B-36.

Packard Terminal

Crimp Tools

terminal into chamber. See Figure B-35.

Appendix B B-23

Content .. 30 31 32 33 ..