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Torque seal on a 12 year old crimp connection almost cost me a whole rewiring job
I found a relay terminal where the crimp looked solid but a continuity test passed and then a quick tug test failed under a bench harness in Denver last month, so has anyone else started doing a manual pull test on every terminal before closing up a panel, even if it passed the tester?
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morgan.joseph9d ago
the real issue might be the solder wicking up the strand under that crimp, not the crimp itself. torque seal hides corrosion but it can also trap moisture against the terminal, and over a dozen freeze thaw cycles in denver that turns into a tiny electrolytic cell that eats the wire from the inside out. so the visual passes, the meter passes, but the copper is already turned to green powder right where you cant see it. i started giving every crimp a sideways flex test too, not just a straight pull, because that finds the brittle strands way better. and if the terminal feels even slightly loose under the boot, i cut it off and redo it, period. that tug test probably saved you from chasing a gremlin that wouldve showed up at the worst possible time.
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