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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 6.0 KREPAIR AND DIAGNOSIS (SINGLE PAGE)ACCESSORIES & EQUIPMENTIGNITION SWITCH/STEERING LOCKWIRING SYSTEMS AND POWER MANAGEMENT - TROUBLESHOOTING & DIAGNOSISDELPHI CONNECTORS (MICRO .64)REPAIR PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.0 K

Repair Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.0 KSECTION Repair Procedure

Follow the steps below in order to repair Micro 64 connector terminals.

The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time.

After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals.

IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire.
  1. Cut the wire as close to the damaged terminal as possible.
  2. Strip 5 mm (3/16 in) of insulation from the wire.
    3. Fig 1: Identifying Crimping Tool Terminal Holder
    GM875015Courtesy of GENERAL MOTORS CORP.
  3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible.
    4. Fig 2: Identifying Terminal Holder
    GM875016Courtesy of GENERAL MOTORS CORP.
  4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator.
  5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings.
  6. Compress the handles until the ratchet automatically releases.
  7. Place the terminal into the appropriate cavity and assemble the connector.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.