04 Wiring
AMPSEAL crimping
Terminals, seals, the right die, and how to release a pin.
6 min readUpdated 2026-08
AMPSEAL 1.0 (the 23- and 35-way used here) is not Superseal 1.0 and it is not a weather-pack. Use the matching terminal and a proper die. A pair of pliers will give you a joint that fails on the first heat cycle.
Parts
| Item | TE part |
|---|---|
| Terminal | 770854-1 (gold recommended) |
| Wire seal | Sized to the insulation OD — do not mix 1.0 mm seals onto 2.0 mm TXL |
| Cavity plug | Fill every unused cavity. An open hole is a water path. |
| Plugs | 776164-1 (A), 770680-1 (B), 776164-2 (C) |
Crimp
01Strip
Short strip. Conductor crimp on the copper, insulation crimp on the jacket. If you can see copper past the insulation crimp, you stripped too much.
02Seal first
Slide the wire seal on before you crimp. You will not get it over a finished terminal.
03Die
Use an AMPSEAL / TE 4-indent or OEM-equivalent die. A pull test should destroy the wire before the crimp slips.
04Insert
Push until it clicks. Tug. Then slide the TPA lock. If the TPA will not close, a terminal is not fully in.
Release
Open the TPA. Depress the cavity latch with the official extraction tool (or a carefully filed pick — this is how you break latches). Pull the wire. Do not yank the terminal through the front of the plug.