Instruction Sheet

AMPSEAL* Automotive Plug Assemblies 408-3229

776268-[ ], 776273-[ ], 770680-[ ], and 776164-[ ] 04 APR 11 Rev F

Housing Red Wedge Lock 3. ASSEMBLY PROCEDURE

(Closed Position)
CAUTION NEVER remove the red wedge lock from the
Contact
housing.
Cavities
!
3.1. Contact Insertion
1. Ensure that the contacts are properly crimped.
Wires
2. Check that the red wedge lock of the plug
Locking Latch assembly is in the open position. If it is not in the
(2 Places) open position, refer to Step 1 of Paragraph 3.2.

NOTE
The plug assembly is supplied with the red wedge
lock in the open position. DO NOT attempt to insert
Wire Side of Cover
any contacts with the red wedge lock in the closed
Plug Assembly i position.
3. From the wire size of the plug assembly, align the
Figure 1
contact with the applicable contact cavity, then
1. INTRODUCTION insert the contact until there is an audible or tactile
click. Refer to Figure 2. DO NOT force the contact.
This instruction sheet covers contact insertion and If the contact is difficult to insert, check that the red
extraction procedures for AMPSEAL Automotive Plug wedge lock is fully open.
Assemblies 776268-[ ], 776273-[ ], 770680-[ ], and
776164-[ ]. NOTE If an empty contact cavity is inadvertently pierced,
insert Seal Plug 770678-1, large end first, into the
Dimensions in this instruction sheet are in metric contact cavity as far as it will go to re-seal it.
NOTE
units [with U.S. customary units in brackets]. i
Figures are not drawn to scale.
i 4. Pull wire slightly (force between 4 and 9 N [1 and
2 in.-lbs]) to ensure that the contact has engaged
For information on contact crimping and mating the retention fingers of the contact cavity. See
header assemblies, refer to the instruction sheet Figure 2.
packaged with the product. I

Instruction sheet packaged with product is: Inserting Contact

NOTE
408-3284 — AMPSEAL Automotive Contacts
770520-[ ] Contact Partially in Wire Seal
i 408-3285 — AMPSEAL Automotive Header Contact Cavity Pierced (Ref)
Assemblies 770669-[ ]

Reasons for reissue of this instruction sheet are

provided in Section 5, REVISION SUMMARY.

2. DESCRIPTION
The plug assembly consists of a housing with contact Contact Engaged by
cavities, cover, red wedge lock, wire seals, and mating Pull Wire to Ensure Retention Fingers
seal. See Figure 1. Engagement

Each contact cavity contains a wire seal that protects

the contact cavity from contaminates. During contact
insertion, the wire seal is pierced as the contact
passes through the contact cavity. Empty contact
cavities will remain sealed. The mating seal provides a
tight closure for mated connectors. The red wedge
lock is used to lock fully seated contacts in the Figure 2
housing.

©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 2
All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service,
*Trademark visit our website at www.te.com
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. LOC B
 408-3229

5. After all contacts have been inserted, close the

Opening Red Wedge Lock
red wedge lock by simultaneously squeezing the
locking latches inward, and pushing the red wedge
lock into the housing until it is flush with the edge of Insert Tip of Edge of
the housing. See Figure 3. Screwdriver Here Housing

Closing Red Wedge Lock

Edge of
Housing

Squeeze
Locking Latch

Red Wedge Lock

in Closed Position

Figure 4
Push Red
Wedge Lock
Removing Contact
Squeeze
Locking Latch Red Wedge Lock
in Open Position
Figure 3

3.2. Contact Removal

1. Move the red wedge lock to the open position as
follows:
a. Insert the tip of a screwdriver having a blade
between 2 and 5 mm [.078 and .196 in.] wide Rotate and
between the edge of the plug assembly Pull Wire
housing and one corner of the red wedge lock
See Figure 4.
b. Gently pry the edge of the red wedge lock
Figure 5
until it is released from (but not completely out
of) the housing.

CAUTION Be careful not to break any part of the assembly
when releasing the red wedge lock.
! Discard and replace any defective or damaged
c. Repeat these steps for the opposite corner
of the red wedge lock. The red wedge lock is
now in the open position.
2. Gently pull the wire of the contact to be removed
while rotating the wire (a quarter turn each direction)
back and forth until the contact is removed from the
housing. See Figure 5.
4. REPLACEMENT AND REPAIR
The contacts and plug assemblies are not repairable.
contacts or plug assemblies. DO NOT re-use a
terminated contact by removing the wire.
5. REVISION SUMMARY
Revisions to this instruction sheet include:
• Changed company logo

Rev F 2 of 2