019-207   Deutsch HD10 Connector Series

Pin Replacement

TOC

These connectors are available with multiple pin configurations.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair wire. Replace one contact at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

Unlock the connector. Rotate the locking tab counterclockwise by hand. Do not use pliers; they can damage the connector.

Remove the two clamp capscrews (1) from the rear of the connector. Turn the rear support of the connector counterclockwise until the two pieces are separated.

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These connectors are available with multiple pin configurations.

Use the Deutsch extraction tool, listed in the table below, to remove a pin from the connector.

Tool Part Number Wire Size
3824815 20 gauge
3822760 16 gauge
3824816 12 gauge

Replace one contact wire at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

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Push the tool into the connector approximately 25 mm [1 in] until it bottoms on the terminal flange.

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Hold the tool on the terminal flange and pull the wire and the connecting pin out of the connector. Note and record the hole from which the pin is removed.

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NOTE: The repair wire is 127 mm [5 in] long.

Remove about 6 mm [¼ in] of insulation from the wire.

Before installing the new repair wire, perform a test fit to make sure the wire is the correct size.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair wire.

Replace one contact wire at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

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Install a repair wire on the bare wire. Make sure the bare wire extends into the splice.

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Use wire crimping tool, Part Number 3822930, to crimp the repair wire onto the bare wire.

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Insert the pin into the correct hole of the connector.

The pin must lock into place and hold the wire in the connector.

Pull the wire gently to make sure it is seated in the connector.

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Install the rear connector support.

Tighten the two wire clamp capscrews.

Torque Value:  1  n.m  [9 in-lb]

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Connector Replacement

TOC

These connectors are available with multiple pin configurations.

Use the Deutsch extraction tool, listed in the table below, to remove a pin from the connector.

Tool Part Number Wire Size
3824815 20 gauge
3822760 16 gauge
3824816 12 gauge

Replace one contact wire at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

SMALL | MEDIUM | LARGE
   


Push the tool into the connector approximately 25 mm [1 in] until it bottoms on the terminal flange.

SMALL | MEDIUM | LARGE
   


Hold the tool on the terminal flange and pull the wire and the connecting pin out of the connector. Note and record the hole from which the pin is removed.

SMALL | MEDIUM | LARGE
   


Before installing the new connector, perform a test fit to make sure the connector is keyed correctly.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair connector.

Refer to the wiring diagram in Section E for pin locations.

SMALL | MEDIUM | LARGE
   


Insert the pins into the correct holes of the replacement connector.

The pin must click into place and hold the wire in the connector.

Pull the wire gently to make sure it is seated in the connector.

SMALL | MEDIUM | LARGE
Last Modified:  09-Oct-2003

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