Terminal Removal Procedure

The JST connector family consists of seven unique connector housings differentiated by color and keying. This connector family is designed to use both 0.64 and 2.8 sized terminals.

Fig 1: Terminal Position Assurance (TPA)
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1. While depressing the lock, remove the connector from the component.
Fig 2: TPA On Both Sides Of Connector
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2. Unlock the terminal position assurance (TPA):
   • Position connector as shown (above) and locate TPA staging cavities.
     Fig 3: Terminal Release Tool

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   • Using connector terminal release tool J-38125-553 (1) lift the TPA into the staged position. Perform this step on both sides of the TPA.
     Fig 4: TPA In Staged Position

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   • You will feel the TPA click into place when fully extended into the staged position. The figure above shows the TPA (1) in the staged position.
Fig 5: Connector Terminal Release Tool
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3. Release the terminal from the connector:
   • Position the connector as shown (above) and locate the terminal release entry canal (1) of the suspect terminal.
   • Insert the connector terminal release tool J-38125-553 into the entry canal with the angled side of the tool facing the connector wall containing cavity 4 (2).
     Fig 6: Connector Lance And TPA

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   • The cavity on the left (1) is a 2.8 mm² cavity and the cavity on the right (2) is a 0.64 mm² cavity.
   • Place the tip of the connector terminal release tool onto the connector lance (3) and deflect the lance to the right (5) to release the lock. Hold this released position.
   • Holding the lance in the released position, slightly pull on the suspect terminal to remove it from the connector housing. The side TPA (4) is a secondary lock.
4. Repair the terminal by following the Repairing Connector Terminals (Terminated Lead Repair) Repairing Connector Terminals (Terminal Repair)  procedure.
5. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies.