Electrical Connector Handling

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Electrical connectors must not be forcibly mated or unmated. All are designed to be mated easily. If you have to use tools, you may be doing something wrong. Prying or forcing connectors may cause permanent damage to the locking mechanism, contacts, or both.

When working on connectors, make sure you are working on the correct terminal. Remember that male and female halves are mirror images of one and other. Look for the terminal number on the connector body. The connection of improper electrical circuits can cause unusual electrical symptoms.

When an electrical connector is repaired, it is important that the proper terminals are used. In some of these connectors, different terminals are used to carry different currents. If contacts of different materials are mated, corrosion may develop that could affect performance.

When removing terminals from a connector, it is very important to use the correct extraction tool and gently remove the terminal. The connector body can be damaged if terminals are just "jerked" out of it. The damage caused will prevent the new terminal from staying in the connector and cause replacement of the connector body.

When installing a new terminal on a wire, make sure the insulation crimp and wire crimp are both made properly. Each part of the terminal crimps is designed for a specific purpose. Failure to properly crimp the wire contact area can result in poor or no electrical contact. Failure to crimp the insulation support properly can result in problems getting the terminal into the connector body, thus causing premature failure.