Automotive wire connectors

Automotive wire connectors

have many shapes and sizes but one of the most useful I have found is the weather pack connector or Delphi Packard Weatherpack. They come with 1,2,3,4 or 6 conductors, there is also a round 5 conductor and a square 4 conductor. These automotive wire connectors are used in GM vehicles but are very common in the after market due to their ease of assembly and the fact that they are reusable. The terminals are easy to remove and reconfigure to your needs. Weather packs are dirt and water resistant. The max recommended current for a weather pack is 30 amps. Terminals for these connectors range from 22 to 12 gauge.

wire connector

Four conductor weatherpack connector

Female weatherpack connector

Female weatherpack connector

automotive wire connectors

automotive wire connectors

Weather pack connectors

Weather pack connectors


How to crimp a weather pack connector terminal.

First thing to do when crimping a weather pack terminal is to select the correct gage terminal for the wire being used. Weatherpack terminals are available in 22-18 gauge, 16-14 gauge and 12 gauge sizes. You will also need a wire seal for each terminal. The seals come in different sizes and are color coded for different wire gage size. Green is for 20-18 gauge Grey is for 16-14 gauge and Blue is for 12 Gauge wire.

20-18 gage wire seals

20-18 gage wire seals

16-14 gage wire seals

16-14 gage wire seals

To begin the crimping process slide a cable seal over the wire and leave some room for striping.wire seal Strip about 3/16″ off the end of the wire.

wire seal on striped wire

Striped wire

Next position the cable seal flush with the wire insulation, leaving the striped portion of the wire exposed.

Seal in position to be crimped

Seal in position to be crimped

Now place the end of the wire into the terminal and ensure that the seal is lined up with the tangs at the end of the terminal. If the wire is striped to the correct length the copper strands should just be just shy of entering the tubular part of the terminal.

Terminal and wire ready for crimping

Terminal and wire ready for crimping

 

Hold the wire and terminal together and place into the correct crimping slot in the tool. The copper strands are crimped first. Note the pockets in the tool how they form the wings of the terminal in the pictures.

Weather pack crimping tool

Weather pack crimping tool

crimping a terminal

Weather pack terminal placed in crimping tool

weather pack tool forming a terminal

Forming terminal wings

Crimping the wire seal

Crimping the wire seal

This is how a finished terminal crimp should look like.

Completed crimp

Completed crimp

The crimping is complete just slide the terminal into the weathpack connector until it clicks into place and then snap the retainer down over the rear of the connector.

Weather pack automotive wire connector
weatherpack automotive wire connector

automotive wire connector

wire inserted into connector