Ford Fusion: General Information / Wire Terminal Inspection and Removal. General Procedures

Disconnect

1.   WARNING: Before beginning any service procedure in this section, refer to Health and Safety Precautions in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

NOTE: To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D or Terminal Probe Kit 29-011A must be used to connect test equipment or jumper wires to pins (terminals).

• Male to female pin (terminal) fit is critical for correct connection and durability.
• Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal separation force (a damaged pin or terminal will have very low separation force from the mating pin or terminal).
• Correctly checking the separation force of small pins (terminals) may require removal of the connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or removal.
• For more detail on the replacement of damaged connectors or pins (terminals) refer to the video below.

1. NOTE: The connector hard-shell information, which is measured in millimeters is the distance from the front face of the connector to the engagement point on the terminal release tang. Mark the listed distance on the terminal removal tool prior to removing the terminal.

   NOTE: The dimensions of the connector hard-shell and the connector terminals release tang are listed above the corresponding graphics.

1. 
   

     Audio Front Control Module (ACM), Body Control Module (BCM) and Instrument Panel Cluster (IPC) Electrical Connector

   
   

   Callout	Connector
   1	External terminal release tang
   2	Electrical connector locking tab

1. 
   

     Audio Front Control Module (ACM), Front Controls Interface Module (FCIM), Gateway Module A (GWM), and Heating, Ventilation and Air Conditioning (HVAC) Control Module Electrical Connector

   
   

   Callout	Connector
   1	Distance to release tang - 0.2953  in ( 7.5  mm) (inner terminal) - 0.4646  in ( 11.8  mm) (outer terminal)
   2	Terminal width size - 0.0244  in ( .62  mm) (inner terminal) - 0.1102  in ( 2.8  mm) (outer terminal)

1. 
   

     Body Control Module (BCM) Electrical Connector

   
   

   Callout	Connector
   1	Terminal width size - 0.1102  in ( 2.8  mm) (inner terminal) - 0.2480  in ( 6.3  mm) (outer terminal)
   2	Distance to release tang - 0.1260  in ( 3.2  mm) (inner terminal) - 0.1575  in ( 4  mm) (outer terminal)
   3	Terminal width size - 0.0591  in ( 1.5  mm)
   4	Distance to release tang - 0.3780  in ( 9.6  mm) (lower terminal)

1. 
   

     Body Control Module (BCM) Electrical Connector

   
   

   Callout	Connector
   1	Terminal width size - 0.0591  in ( 1.5  mm) (inner terminal) - 0.1102  in ( 2.8  mm) (outer terminal)
   2	Distance to release tang - 0.3780  in ( 9.6  mm) (inner terminal)
   3	Distance to release tang - 0.1575  in ( 4  mm)
   4	Distance to release tang - 0.1575  in ( 4  mm)
   5	Terminal width size - 0.2480  in ( 6.3  mm)

1. 
   

     Body Harness In-line Electrical Connector

   
   

   Callout	Connector
   1	Distance to release tang - 0.3346  in ( 8.5  mm)
   2	Terminal width size - 0.1102  in ( 2.8  mm)
   3	Terminal width size - 0.0591  in ( 1.5  mm)
   4	Distance to release tang - 0.3858  in ( 9.8  mm) (inner)

1. 
   

     Body Harness In-line Electrical Connector

   
   

   Callout	Connector
   1	Distance to release tang - 0.3543  in ( 9  mm)
   2	Terminal width size - 0.0591  in ( 1.5  mm) (inner terminal) - 0.1102  in ( 2.8  mm) (outer terminal)
   3	Terminal width size - 0.2480  in ( 6.3  mm)
   4	Distance to release tang - 0.3543  in ( 9  mm)

1. 
   

     Body Harness In-line and Seat Harness Electrical Connector

   
   

   Callout	Connector
   1	Distance to release tang - 0.4331  in ( 11  mm)
   2	Terminal width size - 0.0591  in ( 1.5  mm)
   3	Terminal width size - 0.0591  in ( 1.5  mm)
   4	Distance to release tang - 0.4331  in ( 11  mm)

1. 
   

     Body Harness In-line and Seat Module Electrical Connector

   
   

   Callout	Connector
   1	Terminal width size - 0.0591  in ( 1.5  mm)
   2	Distance to release tang - 0.3937  in ( 10  mm)