Delphi GT 280 terminal removal

[Motown 454]

Does anyone know of a video showing how to remove the terminals from a Delphi GT 280 connector? I have the removal tool ? I can find a weather pack video but the tool and terminal are different. I've tried 4 times and every time my blood pressure has gone up another 100 points when I can't get them out. I want to re pin them into another connector with more cavities to consolidate a couple of harnesses.

This is the new connector.

https://static1.pt-content.com/images/pt/2015/05/th__35_zpshc8e19us-1.jpg (http://s172.photobucket.com/user/Hardcore454/media/Fuel%20system/_35_zpshc8e19us.jpg.html)

This is the actual connector I'm trying to get the terminals out of.

https://static1.pt-content.com/images/pt/2015/05/th_DSCN0055_zpsmhmiwnc8-1.jpg (http://s172.photobucket.com/user/Hardcore454/media/Fuel%20system/DSCN0055_zpsmhmiwnc8.jpg.html)

https://static1.pt-content.com/images/pt/2015/05/th_DSCN0056_zpsff5taytz-1.jpg (http://s172.photobucket.com/user/Hardcore454/media/Fuel%20system/DSCN0056_zpsff5taytz.jpg.html)

Thank you for any help.

[CarlC]

I have the tool and never could make it work. So, start by removing (if aplicable) the Termial Position Assurance clip near the where he wires go in to the plug body.

For the female terminals (the RH plug in your photo), it's very easy to remove the end cap to gain access to the face of the terminal. You can use your tool, but I found it easier to use a jewlers scredriver to very gently pry up on the locking tab that holds the terminal. Then pull the wire/terminal assembly out. A magnifier makes it much easier to see. Be careful not to pry up too much or the tab will break. I usually gently twist the jewlers screwdriver while pulling the wire so that it will release just as it comes free.

The male terminals release the same way but getting the end cap out is a bit harder. A pick with a curly end, or a small "L" shape can be used to grab the cap through the holes and pull it out.

[parsonsj]

I use .040 welding wire and make a 90* bend on the end with pliers. It just needs to go on the inside at the two ends of the blue oval thingie (TPA). Then pull the TPA up and off. You'll have to work both sides. It doesn't take much force. Once the TPA is off, the rest is obvious.

jp

[CarlC]

jp,

In Delphi's nomenclature they consider the long thin clip that inserts near the wire seals the TPA clip.

However, the grey, sometimes purple, end cap has a terminal insertion position and a locked position. Trying to remove the terminal with the cap in the locked position is super hard. The same is true when inserting a terminal. It can be forced it, but releasing the cap makes it much easier.

[andrewb70]

As Carl said, the TPA is the thing that goes behind the wires and keeps the seals and terminals from backing out in case there is an issue with the internal locking clips. I can maybe make a quick video tomorrow.

I've found that for the female connectors (that use the female terminals) the caps come off easily enough. For the male connectors (that use the male terminals) the caps are much harder to remove. That said, once you understand how the male terminals are retained in the connector body, a thin terminal removal tool works quite well (for me at least).

Andrew

[parsonsj]

OK, the blue oval thing in the picture is an "end cap"? I'll fix my post to say that rather then TPA, thanks!

[parsonsj]

About the force needed to remove the end cap... I didn't find it that hard. It was mostly a matter of not being able to get to it in the female body (story of my life, lol)

[parsonsj]

Here's the connector with the end cap removed:

113602

[Motown 454]

Thanks guys, I did one with the cap still on and got the other, once I realized it was removable. After 200 kuss words and 10 temper tantrums and begging the lord for patients I finally got them out and re pinned. And like you said after you see it opened it is obvious. I have a bad habit of using 200 ft lbs of pressure when something needs 10 inch pounds and I didn't want to destroy the connector. It became a matter of pride to get it done.
Thanks again.

Do they make a secondary lock for the GT 280 ?

[CarlC]

Secondary locks (that holds the release tab on the female connector holding it to the male) are available but are not really needed. It takes quite a lot to get the tab to release.

Just for clarification, Delphi terms the connector body by the terminal type. Even tough it appears female, the connector in Andrew's photo is male.

For some light reading here is the Delphi Global Connections Catalog. Though there is much information, some of the supposedly compatible GT280 and 150 connectors don't fit together. There a different versions of the same connector, and they are not interchangeable. The best way to is check stock on Mouser, pull up the Delphi data sheet, and check for mating parts. https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&ved=0CB4QFjAA&url=https%3A%2F%2Fwww.powerandsignal.com%2Fdocs%2F DCS%2520Global%2520Catalog.pdf&ei=WOVxVdueFMSZsAW-tIHwCg&usg=AFQjCNHzPR-kTu7ss_7pmVapewsx1szQSw&bvm=bv.95039771,d.b2w