Installing a Solderless Terminal

Solderless terminals are used by the factory throughout the vehicle, primarily at connectors. If a wire itself needs to be repaired, it should be soldered back together instead of using solderless terminals to reconnect the wires. Solderless terminals are quick to install and effective at conducting electricity across joints that are designed to be disconnected. Solderless terminals require a clean, tight connection. It is important to make sure the wire and the connection are clean before attaching any terminals. You should use connections that match the size of the wire. Many solderless connectors are color coded for the size of wire they are designed to work with, such as yellow 12-10 AWG, blue 16-14 AWG, and red 22-18 AWG. Use the correct wire stripper to strip only as much insulation off as needed to allow the wire to fully engage the terminal. To keep the wires together after stripping them, give them a slight twist. Do not twist the wire too much; otherwise you risk a poor wire-to-terminal connection. Use the correct crimping tool for the connection. Using the wrong type of tool will cause the connection to have a poor grip on the wire.

To install a solderless terminal, follow the steps in Skill Drill 36-2:

1
Select the terminal for the wire and connector you are using. There are different types and sizes of wire terminals, but the procedure for installing all of them is the same. Make sure you have the correct size of terminal for the wire to be terminated and that the terminal has the correct volt/amp rating for the job it is to perform.
2
Remove an appropriate amount of the protective insulation from the wire with the proper stripping tool. (Photo 1)
3
You will get a better connection if you do not twist the strands together tightly before placing them through the terminal, as this gives the terminal more surface area to come in contact with the wires when crimped. However, it can be difficult to insert the wires into the terminal if they are loose strands. Twist them together just enough to help you insert them cleanly. Place the solderless terminal onto the wire. It is important that the stripped end of the wire be flush with, or only slightly beyond, the crimping portion of the terminal. (Photo 2)
4
Use the proper crimping pliers for the terminal you are installing. Do not use standard pliers, as they have a tendency to cut through the connection, which can cause trouble during service. Select the proper anvil for the connector or terminal selected. (Photo 3)
5
Crimp the core section first. Use firm pressure so that a good electrical contact will be made, but not excessive force, as this can deform the pin or terminal. (Photo 4)
6
If crimping an uninsulated terminal, lightly crimp the insulation tabs so that they hold the insulation firmly. (Photo 5)
7
A note about alternative terminals: Some types of crimp terminals do not have an insulation component fixed to them. These come in two parts, and the insulator is supplied as a separate component. In these cases, always make sure the core of the wire to be crimped extends through the core tabs in the terminal.
SKILL DRILL
36-2
Installing a Solderless Terminal
24118_CH36_SKDSD02_01
1
Make sure you have the correct size of terminal for the wire to be terminated and the terminal has the correct volt/amp rating. Remove an appropriate amount of the protective insulation from the wire.
24118_CH36_SKDSD02_02
2
Lightly twist the wire strands and place the terminal onto the wire.
24118_CH36_SKDSD02_03
3
Use a proper crimping tool for the terminal you are crimping. Do not use pliers, as they have a tendency to cut through the connection. Select the proper anvil.
24118_CH36_SKDSD02_04
4
Crimp the core section first. Use firm pressure so that a good electrical contact will be made, but not excessive force, as this can bend the pin or terminal.
24118_CH36_SKDSD02_05
5
If crimping an uninsulated terminal, lightly crimp the insulation tabs so that they hold the insulation firmly.