DDEC III/IV Single ECM Troubleshooting

Section 8.3 Weather Pack and Metri-Pack 280 Connectors

Section 8.3
Weather Pack and Metri-Pack 280 Connectors

Weather Pack and Metri-Pack 280 series connectors are push-to-seat. The terminal is crimped onto each wire before it is inserted into the connector. A cable seal is crimped on each wire at the same time the terminal is crimped onto the wire. Weather Pack connectors use a secondary lock on both male and female connector bodies and the lock snaps into place over the cable seals after installation. Some Metri-Pack connectors have secondary locks as well. Weather Pack connectors and their associated part numbers are listed in Table "Weather Pack Connectors and Part Numbers" . Metri-Pack 280 connectors and their associated part numbers are listed in Table "Metri-Pack 280 Connectors and Part Numbers" . ‪

Turbo Boost Pressure Sensor Harness

Engine Brake Connector, Series 60

Connector‪

P/N: 12015384‪

Connector‪

P/N: 12010973 / 12162000‪

Terminal‪

P/N: 12089040‪

Terminal‪

P/N: 12048074 / 12045773‪

Seal‪

P/N: 12015323‪

-‪

-‪

Throttle Position Sensor Harness Side

Throttle Position Sensor Sensor Side

Connector‪

P/N: 12015793‪

Connector‪

P/N: 12010717‪

Terminal‪

P/N: 12089188‪

Terminal‪

P/N: 12089040‪

Seal‪

P/N: 12015323‪

Seal‪

P/N: 12015323‪

Plug‪

P/N: Not Applicable‪

Plug‪

P/N: Not Applicable‪

Ignition Connector Power Harness Side

Ignition Connector Vehicle Interface Harness Side

Connector‪

P/N: 12034074‪

Connector‪

P/N: 12015378‪

Terminal‪

P/N: 12089040‪

Terminal‪

P/N: 12089188‪

Allison Interface Module

Allison Interface Module Maximum Feature

Connector‪

P/N: 12015791‪

Connector‪

P/N: 12015799‪

Terminal‪

P/N: 12089188‪

Terminal‪

P/N: 12089188‪

Seal‪

P/N: 12015323‪

Seal‪

P/N: 12015323‪

Plug‪

P/N: 12010300‪

Table 1. Weather Pack Connectors and Part Numbers

Coolant Level Sensor Connector

Power Harness

Connector‪

P/N: 15300027‪

Connector‪

P/N: 12124634‪

Terminal‪

P/N: 12077411‪

Terminal‪

P/N: 12077413‪

Seal‪

P/N: 12015323‪

Seal‪

P/N: 12015193‪

Secondary Lock‪

P/N: 15300014‪

Secondary Lock‪

P/N: 12052816‪

Plug‪

P/N: Not Applicable‪

Plug‪

P/N: Not Applicable‪

Table 2. Metri-Pack 280 Connectors and Part Numbers

Section 8.3.1
Installation

Use the following instructions for terminal installation: ‪

  1. Insert the terminal into the locating hole of the crimping tool using the proper hole according to the gage of the cable to be used. See Figure "Terminal Position " .
    Click to see this graphic in a separate window

    Figure 1. Terminal Position

  2. Insert the cable into the terminal until the stripped portion is positioned in the cable core wings, and the seal and insulated portion of the cable are in the insulation wings. See Figure "Cable and Terminal Position Before and After Crimping " .
    Click to see this graphic in a separate window

    Figure 2. Cable and Terminal Position Before and After Crimping

  3. Compress the handles of the crimping tool until the ratchet automatically releases and the crimp is complete. A properly crimped terminal is shown. See Figure "Cable and Terminal Position Before and After Crimping " .
  4. Release the crimping tool with the lock lever located between the handles, in case of jamming.
  5. Push the crimped terminal into the connector until it clicks into place. Gently tug on the cable to make sure it is secure. See Figure "Inserting Terminal in Connector " .
    Click to see this graphic in a separate window

    Figure 3. Inserting Terminal in Connector

Section 8.3.2
Removal and Repair

Two locking tangs are used on the terminals to secure them to the connector body. Use the following instructions for removing terminals from the connector body.‪

  1. Disengage the locking tang, securing the connector bodies to each other. Grasp one half of the connector in each hand and gently pull apart.
  2. Unlatch and open the secondary lock on the connector. See Figure "Unlatched Secondary Lock " .
    Click to see this graphic in a separate window

    Figure 4. Unlatched Secondary Lock

  3. Grasp the cable to be removed and push the terminal to the forward position.
  4. Insert the removal tool straight into the front of the connector cavity until it stops.
  5. Grasp the cable and push it forward through the connector cavity into the tool while holding the tool securely in place. See Figure "Removal Tool Procedure " .
    Click to see this graphic in a separate window

    Figure 5. Removal Tool Procedure

  6. The tool will press the locking tangs of the terminal. Pull the cable rearward (back through the connector). Remove the tool from the connector cavity.
  7. Cut the wire immediately behind the cable seat and slip the new cable seal onto the wire.
  8. Strip the end of the cable using strippers to leave 5.0 ± 0.5 mm (0.2 ± 0.02 in.) of bare conductor. Position cable seal as shown. See Figure "Proper Cable Seal Position " .
    Click to see this graphic in a separate window

    Figure 6. Proper Cable Seal Position

  9. Crimp new terminal onto wire using the crimp tool. See Figure "Crimping Procedure " .
    Click to see this graphic in a separate window

    Figure 7. Crimping Procedure


DDEC III/IV Single ECM Troubleshooting Guide - 6SE497
Generated on 10-13-2008

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