1 September 2011
d. Insert tool into contact cavity until tool tip
bottoms against contact shoulder. A slight increase in
Removal tool may be blocked at rear of
resistance will be noticed just before the tool tip
contact by plastic insert or additional strands
bottoms. This will spread the retention clip and release
of broken wire.
its hold on the contact.
e. Press wire firmly against serrated edge of
reaches back end of contact, withdraw tool slightly,
removal tool and pull wire straight out from contact
rotate about l/6 of a turn, and reinsert tool. Repeat
rotating and insertion procedure until tool passes with
minimum additional force to 5/16 inch depth back end
38. Broken Wire Contact Removal.
e. Wiggle removal tool gently to help it into
insert bore and over back of contact. Additional
rotation may be required if broken strands are
Caution should be exercised in the use of
tooling. Inspect tips of metal tools for
f. Continue insertion of removal tool until
distortion of the probe before use, as damage
positive stop is felt at about l/2 inch depth.
to the wire sealing grommet of the connector
g. Exert axial pressure on engaging end of
contact, using appropriate pin or socket as pusher. If
Select correct removal tool (Figure 3).
contact does not move, seat removal tool more firmly.
b. Insert tip of removal tool about l/8 inch into
cavity at rear of connector.
When removing broken wire contacts ensure
wire sealing grommet is not damaged. A
new connector must be installed (Paragraph
Wire strands may be encountered at any
39) if a broken wire contact cannot be
point up to 5/16 inch of tool insertion. It is
important not to jam any strands of wire up
to this point.
h. Push contact completely out of rear of
connector before disengaging removal tool.
Withdraw removal tool anytime during
insertion when it cannot be advanced into
39. CONNECTOR REMOVAL AND
connector using these procedures.
INSTALLATION. If the connector is severely
damaged or cannot be repaired using the above
Inspect tool tip for nicks, cracks,
procedures, proceed as follows:
mushrooming, and other damage that will
prevent functioning. Replace removal tool
a. Starting from outside of damaged connector,
and repeat procedure, if required.
tag wires and remove all contacts from connector
Paragraph 36). If contact cannot be removed, cut wire
c. Gently insert removal tool into cavity in
as close to connector as possible and attach new
about l/16 inch units, releasing tool after each unit if
contact (Paragraphs 33 and 34).
resistance is felt.
b. Starting from center of new connector, insert
contact into correct cavity (Paragraph 35). Remove
Rotating removal tool works splayed wire
tag from wire. Repeat procedure until all contacts are
strands into slot of tool, allowing too1 to
installed in new connector.