Lead Terminal Repair. General Procedures

Materials

Repair

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
2. 2
   Bring the vehicle to the specified room temperature or higher.
   Temperature: 60.8 °F (16 °C)
3. 3
   • Terminal Kit - Rear Window 4F1Z-14421-AA

   Clean the bus bar in the area to be repaired using steel wool (grade 000 to 0000), then use glass cleaner to remove all dirt, wax, grease, oil or other foreign material.
   Material: Motorcraft® Ultra-Clear Glass Cleaner Spray / ZC-23 (ESR-M14P5-A)
4. 4

   NOTICE: Do not use any flame torches or flame-heated soldering irons for this procedure. Using these tools does not allow heat transfer to the tip and exhaust heat may damage plastic trim parts in this area. Use only an electric soldering iron with a power of 100 W or more. Before using the soldering gun, be sure to melt a small amount of solder flux onto the tip. The solder will help achieve better heat transfer from the soldering gun tip to the new terminal.

   Place the replacement type A terminal over the original tab location, ensuring that the conductive portions of the terminal are on a highly conductive area. Do not place the terminal tab over the original location if it does not have conductive material.
5. 5
   Hold the terminal in place with an object such as a regular graphite pencil at a 90-degree angle to the terminal (holding it at an angle other than 90 degrees may cause the terminal to slip when the solder liquefies).
6. 6
   Place the tip of the soldering iron on the top of the terminal, but not on the painted areas of the tab. Turn on the soldering iron and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy approximately 25-45 seconds after heating. Once the paint color has fully changed on either side of the terminal, de-energize the soldering iron and continue holding the terminal in place with the soldering iron and pencil for another 30 seconds.
7. 7
   Remove the soldering iron and the pencil from the terminal. Allow the terminal to cool for an additional 2 minutes before attaching the wires to the terminal.
8. 8
   Connect the electrical wire to this terminal, turn on the rear window defroster and check its operation.