Checking Terminal Contact

Many tables will have you checking terminal contact before replacing a component. This is done because the checks performed in tables can only check the continuity of a circuit across a wire or in-line connection, not the continuity across the connection at a component. Checking terminal contact will prevent the replacement of good components, prevent comebacks due to intermittent connection problems, and make some repair jobs easier, as in replacing a terminal instead of a component. For this reason it is very important to check terminal contact when instructed to do so.

Checking terminal contact is easy as long as you have a supply of new terminals handy. The J 38125-B terminal repair kit is a good source of terminals for checking terminal contact. It contains a supply of all currently used terminal series and also has the male terminals (12047581) and female terminals (12052922) necessary to build the diagnostic jumper for Ignition Control DTC diagnosis (for the connector part number refer to the Wiring Systems section of Body and Accessories. To check terminal contact, start by inspecting the male terminals. They should be straight and aligned with other terminals in the row. They should not be twisted, bent or otherwise damaged. The female terminal should be, likewise, inspected for alignment and damage. Finally, take a new male terminal of the same series (e.g. Metripack 150, Weatherpack, etc.) and connect it to the female terminals to be checked. It should not fall out or be easily jarred out of connection. It should require some force to disconnect it. The force required to disconnect it will depend on the size of the terminal being checked. Larger terminals, Metripack 630 series for example, should be very difficult to remove by hand. Smaller terminals, Micropack series for example, should be easier to disconnect by hand but still should not fall out. Replace, do not repair, any damaged terminals. Refer to Connector Repairs in Diagrams and J 38125-B terminal repair kit, for identification of terminal series and repair procedures.