How To Crimp Amp Connectors

Crimping AMP (Tyco/TE Connectivity) connectors properly is crucial for reliable electrical connections in automotive, industrial, or electronics projects. Here’s a step-by-step guide to ensure a secure, durable crimp:

Tools & Materials Needed

1. AMP-compatible crimping tool (e.g., TE Connectivity HT-0055, AMP 271-1000).

2. AMP connector terminals (e.g., AMP Superseal, Metri-Pack, or Deutsch-style).

3. Wire strippers (adjustable for the wire gauge).

4. Heat shrink tubing (optional, for insulation).

5. Calipers or wire gauge chart (to verify wire size).

Step-by-Step Guide

1. Select the Correct Terminal & Wire Gauge

• Match the terminal to your wire size (e.g., 16 AWG, 18 AWG, etc.).

• Check the AMP catalog or connector datasheet for compatibility.

• Example: A Metri-Pack 150 series terminal may require 20–16 AWG wire.

2. Strip the Wire

• Use wire strippers to remove 3–4mm of insulation from the wire end.

• Avoid nicking the strands—damaged wires reduce conductivity.

• Tip: If using heat shrink, slide it onto the wire before stripping.

3. Insert the Wire into the Terminal

• Align the stripped wire into the metal barrel of the terminal.

• Ensure all strands are fully inserted—no exposed copper should be visible.

4. Position the Terminal in the Crimper

• Open the crimping tool and place the terminal into the correct die slot (marked for wire gauge).

• The terminal’s insulation crimp (if present) should face the tool’s insulation crimp section.

• Key point: Some AMP tools have color-coded dies (e.g., red for 22–18 AWG, blue for 16–14 AWG).

5. Crimp the Terminal

• Squeeze the crimper handles firmly and evenly until the tool releases.

• You should hear/feel a "click" indicating a complete crimp.

• Two-stage crimping (if applicable):

• First crimp: wire barrel (conductive part).

• Second crimp: insulation barrel (for Strain Relief).

6. Inspect the Crimp

• Visual check: The crimp should be uniform and free of gaps.

• Pull test: Gently tug the wire to ensure it’s secure (should not pull out).

• Cross-section check (advanced): Cut the crimp open to verify full compression (optional).

7. Apply Heat Shrink (Optional)

• Slide heat shrink over the crimp and shrink it with a heat gun for insulation and strain relief.

Common Mistakes to Avoid

1. Using the wrong tool: A generic crimper may deform AMP terminals, leading to poor conductivity.

2. Incomplete insertion: Exposed wire strands can cause shorts or corrosion.

3. Over-crimping: Crushing the terminal too hard may break the wire or terminal.

4. Under-crimping: A loose crimp can cause intermittent connections or overheating.

5. Mixing wire gauges: Using a terminal rated for 16 AWG on 20 AWG wire risks failure.

Pro Tips

• Practice on scrap wire before crimping critical connections.

• Use a magnifying glass to inspect small crimps (e.g., 24 AWG).

• Label wires if working with multiple connections to avoid confusion.

• For high-vibration applications (e.g., automotive), use terminals with secondary locks or strain relief.

AMP Connector Types & Crimping Notes

Final Checklist

✅ Correct terminal for wire gauge?
✅ Wire stripped properly?
✅ Terminal fully inserted?
✅ Crimper set to the right die?
✅ Crimp inspected for gaps/pull resistance?

By following these steps, you’ll achieve professional-grade AMP crimps that resist vibration, corrosion, and environmental damage. For mission-critical applications (e.g., automotive wiring), consider soldering + crimping for extra durability.