#### CONNECTORS

Three types of connectors are commonly used in automotive applications — weatherproof, molded and hard shell.

Fig. 1: Hard shell (left) and weatherproof (right) connectors have replaceable terminals

- Weatherproof — these connectors are most commonly used where the connector is exposed to the elements. Terminals are protected against moisture and dirt by sealing rings which provide a weathertight seal. All repairs require the use of a special terminal and the tool required to service it. Unlike standard blade type terminals, these weatherproof terminals cannot be straightened once they are bent. Make certain that the connectors are properly seated and all of the sealing rings are in place when connecting leads.
- Molded — these connectors require complete replacement of the connector if found to be defective. This means splicing a new connector assembly into the harness. All splices should be soldered to insure proper contact. Use care when probing the connections or replacing terminals in them, as it is possible to create a short circuit between opposite terminals. If this happens to the wrong terminal pair, it is possible to damage certain components. Always use jumper wires between connectors for circuit checking and NEVER probe through weatherproof seals.
- Hard Shell — unlike molded connectors, the terminal contacts in hard-shell connectors can be replaced. Replacement usually involves the use of a special terminal removal tool that depresses the locking tangs (barbs) on the connector terminal and allows the connector to be removed from the rear of the shell. The connector shell should be replaced if it shows any evidence of burning, melting, cracks, or breaks. Replace individual terminals that are burnt, corroded, distorted or loose.

  Fig. 2: Weatherproof connectors are most commonly used in the engine compartment or where the connector is exposed to the elements