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

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

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 " .
   

   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 " .
   

   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 " .
   

   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 " .
   

   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 " .
   

   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 " .
   

   Figure 6. Proper Cable Seal Position

9. Crimp new terminal onto wire using the crimp tool. See Figure "Crimping Procedure " .
   

   Figure 7. Crimping Procedure