Instructions

The Wire Harness Repair Kit has been developed to improve customer satisfaction by simplifying the repair of electrical wiring harnesses. This kit can also save costs and improve dealer service capabilities by making repairs possible rather than the replacement of entire wire harness assemblies.





The Wire Harness Repair Kit contains the components necessary to properly test and repair a wire harness. Use the components according to the instructions in the user guide and parts information booklet included with the kit and as explained below.

The Terminal Tension Gauge is used for measuring the tension of a female terminal.

1. Select the male shaft that matches the female terminal being checked.

2. Select the weight attachment, part number TRK003-6, following these guidelines:





a. TRK003-1, TRK003-2, use both weight attachments.





b. TRK003-3, use one weight attachment.





C. TRK004-4, TRK003-5, do not use any weight attachments.





3. Insert shaft into female terminal.

4. Hold the terminal vertically with the tension gauge hanging from the bottom.

5. If the tension of the female terminal is satisfactory, the tension gauge will not fall out of the female terminal, and there is no need to replace the terminal.

6. If the tension of the female terminal is unsatisfactory, the tension gauge will fall out of the female terminal, if this occurs, remove and replace with a terminal and wire assembly, including a seal when appropriate.

To use the Flat Remover Tool:

Single Locking





1. Select remover tool that best fits the wire terminal to be removed.

2. Insert remover tool into the gap between the plastic release tab and the terminal.





3. Pull gently on wire until terminal pulls free from the connector.

Double Locking





1. Use the largest remover tool (or small flat tip screwdriver) to lift up on the terminal secondary lock.





2. Select the remover tool that best fits the wire terminal to be removed.

3. Insert remover tool into the gap between the plastic release tab and the terminal.





4. Pull gently on wire until terminal pulls free from the connector.

NOTE:
If necessary, clean the inside of the connector with electrical contact cleaner first. After removing the terminal, check for any damage. If there is any damage replace it with a new terminal.