D. Replacing Cable Terminals

Check:

Disconnect connector from control module.

Inspect cable terminals in cavities.

Cable terminals may have been damaged when the connector was installed.

A damaged cable terminal is easily spotted. Both cable terminal lips" must be clearly visible.





The illustration shows cable terminals out of the connector, from the side and magnified.

The left is damaged and the right normal.

Replace damaged cable terminals as follows.

Repair kit

The connector cable terminals necessary for repairing ABS wiring can be ordered in kit 9512607-4.





The crimping tool for ABS connector cable terminals is 9512608-2.

Method of replacing cable terminals

Open the connector cover.





Cut off the tie straps at the connector.





Remove cable terminal secondary locking by pushing the catch (in the shaded area) in the direction of the arrow with a screwdriver.

To disconnect and transfer cables, there are three possible terminal removal tools that can be used.

Alternative A:





From Terminal Repair kit 9814235-9, use terminal removal tool 9814228-4 to disconnect and transfer cables, one at a time, to the new connector. It is important to disconnect one cable at a time so as not to mix them up.

Alternative B:





Use terminal removal tool 9512630-6 for the small cavities and 9512631-4 for the large ones.

Pull the cable and cable terminal to be replaced as far out of the cable harness as possible.

If the cable is twisted together with another cable it must be twisted in the same way with the same cable when the new cable is connected.

Cut off the cable terminal as close to the damaged cable terminal as possible.





Take out a suitable blade receptacle terminal (cable terminal) and seal according to the table above:

Install seal on cable.

Strip the cable according to:

Service Manual Section 3 (37)
TP 3701201
Wiring repairs and replacement of cable terminals
850, 900
Sections EB, FB.





Note:
Wheel sensor cables are twisted pair (positive and negative signal) cables for each wheel.

It is important that paired cables are twisted in the same way when they are reinstalled in the connector. They should be twisted approx. 3 turns per 100 mm (4").





Connector terminal numbering is illustrated above.

The first and last terminals in the outer smaller rows are marked with 1 and 7 and 17 and 23.

The first terminal in the middle row is marked 10.

The large terminals are marked 8 and 9 and 24 and 25.

The table below shows where in the connector each wheel sensor should be connected:

Wheel: Positive signal: Negative signal:

Right rear # 17 # 1
Left rear # 10 # 2
Right front # 3 # 18
Left front # 4 # 11

For cable terminal type identification, see the table at the end of this bulletin.

When crimping is complete

Install cable terminal in connector.

Remove next cable terminal if others are to be replaced and repeat above procedure.

(Note. One at a time)





When all damaged cable terminals have been replaced, secure the cable harness as before with new tie straps.

Large tie strap P/N 948211-8

Small tie strap P/N 948702-6





Lock cable terminal secondary locking by pushing the catch (in the shaded area) in the direction of the arrow with a screwdriver.