60. Broken Wire Contact Removal.
Metal tool tips are sharp and can cause injury
to personnel and/or damage to connectors.
Present metal tooling in some instances has
damaged the wire sealing grommet at the end
of the connectors. Plastic tools are preferred.
Caution should be exercised in the use of
Inspect tips of metal tools for distortion or
nicks of probe before use as connector damage
Figure 20. Typical Connector Dimensions
Select correct removal tool (Table 6).
Gently insert removal tool into cavity in about
/16 inch units, releasing tool after each unit if resistance
Removal of a contact with a broken wire shall
not be attempted with an unwired removal
tool. Use of unwired removal tools requires
Rotating removal tool works splayed wire
that the tip be jammed onto the contact wire
strands into slot of tool, allowing tool to pass.
barrel. If wire strands occupy wire barrel, the
tool and connector may be damaged.
Removal tool may be blocked at rear of contact
by plastic insert or additional strands of broken
b. Insert tip of removal tool about 1/8 inch into
cavity at rear of connector.
d. If resistance is felt before removal tool reaches
back end of contact, withdraw tool slightly, rotate
about 1/6 of a turn, and reinsert tool. Repeat rotating and
Wire strands may be encountered at any point
insertion procedure until tool passes with minimum
up to 5/16 inch of tool insertion. It is important
additional force to 5/16 inch depth back end of contact
not to jam any strands of wire up to this point.
Withdraw removal tool anytime during
Wiggle removal tool gently to help it into
insertion when it cannot be advanced into
insert bore and over back of contact. Additional rotation
connector using these procedures. Inspect tool
may be required if broken strands are encountered.
tip for nicks, cracks, mushrooming, and other
damage that will prevent its functioning.
Continue insertion of removal tool until
Replace removal tool and repeat procedure, if
positive stop is felt at about 1/2 inch depth.
g. Exert axial pressure on engaging end of contact,
using appropriate pin or socket as pusher. (If contact
does not move, seat removal tool more firmly).
Refer to Figure 20 for approximate dimensions
of a size 22 contact and cavity. The dimensions
h. Push contact completely out rear of connector
in this procedure are based on a size 22 contact.
before disengaging removal tool (Figure 22).