Here are a couple tips to hopefully help some of you Remove those Secondary locks and terminals.
There are lots of Different connector housings, terminals and removal procedures for each. I cannot help with all of them.
Manufactures normally make information like crimp height and the removal info available to the end users. You may need to
do some research on the manufactures website, or possibly call/email them personally for the proper links or technical resources.
Removing the Lock-plate or Retainer
Sumitomo HV040 connector cross sectioned
with terminal and seal in place.
Most of the time you will need a tool with a
tapered tip, similar to the tool in the photo
on the right.
You can successfully make something similar with a dremel
or grinder, Careful that you don't break it off in the housing,
Things like paper clips are made of soft metal.
Next you will need to gently pry down on the retainer like in this photo.
(Some connectors like the Molex MX-150 you will need to push inward inserting the tool)
1 - you don't want to put much pressure on the terminal, as this may cause it to bind
on the housing.
2 - you don't want to damage the terminal or housing if either are going to be reused.
Here you can see the retaining lock is moved far enough downward for this terminals
There will be a slot or hole to insert the tool into.
The hole on slot may be in the secondary lock-plate/retainer,
or under the lock plate/retainer and it will have to be removed.
The type of primary retainer will vary by Manufacture and series (I cant cover them all.)
The pick will need to be oriented correctly to engage the terminal retainer as
seen in this photo.
At the same time you disengage the retainer, you will want to pull lightly on the wire.
(you should not have to force it, If it doesn't come right out make sure the tip
of the tool is properly on the retainer.)
NOTE: They are not always easy to remove, and some terminal and housing types
can be very difficult to work with.
Will holding the correct wire on the back side of the housing.
The removal pick will need to be inserted straight in until it stops or bottoms out.
At this point the terminal should come right out.
some types may need a little help along the way and need to be angled up or down.
A secondary lock or retainer is used on many of the newer series connectors
It may serve a couple different functions.
1 - To keep the terminals primary lock in place. (Preventing the terminal from being
pushed out the back of the housing when inserting the mating connector.)
2 - To ensure the terminal is properly inserted and locked into the housing.
(Many of the newer series will not allow the retainer to seat and lock in place
if the terminals are not installed correctly or completely.)
You will need to remove this retainer
before you try to remove the terminal from
On this HX040 female housing, there is a slot on the bottom side of the retainer.
You can use a small screw driver or removal tool to get under the edge and
pry the retainer outward.
Different manufactures and series will have different methods needed to remove
the retainers. The mating male housing for this connector uses a retainer that will
require a small notch in the end of the removal tool, so you can hook the retainer
and pull it outward.
Others like the Molex MX150 series require
nothing more than a small needle nose pliers
to remove retainers.
As the retainer comes up like it suppose to, it may pop off completely or just move
outward some like this one did.
This retainer on this connector needs to be removed completely to get to the terminals
Here is the housing with the retainer removed, and you can now remove the terminal.
Hook inserted into Male retainer
Hook needed to remove
various types of male retainers