What is "Weather Pack"?
Weather Pack is an environmentally sealed electrical connection system developed by Packard Electric engineers (now Delphi/Packard Electric Systems) to withstand exposure to extreme temperatures, moisture, and harsh engine compartment fluids and chemicals. They are extensively used in severe duty applications including racing, construction, off-road, and industrial equipment.
Weather Packs mate heat stabilized polyamide housings (Weather Pack “towers and shrouds”), male and female “pin and socket” Weather Pack terminals and self-lubricating silicone Weather Pack connector seals, cable seals and cavity plugs. The connectors are made of a nylon material for the best combination of temperature resistance and flexibility. They have been tested to withstand temperatures of -40C to 125C. The terminals are tin-plated and utilize flex pin and lap lock designs to provide the highest reliability. Their dual locking tangs securely hold the terminal inside the connector cavity. Weather Pack self-lubricating seals feature multiple sealing ribs and will not stain, deteriorate or corrode other materials.
The system is rated 0.05–16.0 VDC, 0-20A. Weather Pack connector configurations are available for one to six wires
Why are the Weather Pack connectors called Towers or Shrouds instead of male or female connectors?
The use of the "Tower and Shroud" nomenclature eliminates confusion with gender specific connectors. Weather Pack towers are most often used with female terminals but they can also be used with male terminals. Weather Pack shrouds are most often used with male terminals but they can also be used with female terminals. It is even possible to use both male and female terminals in a single multi-circuit Tower or Shroud.
I’ve ordered Weather Pack terminals and connectors. Do I need anything else?
Weather Pack terminals are ALWAYS used with Weather Pack cable seals. One is required for each terminal, male or female. You might also want to order a Weather Pack release tool in case you need to disassemble a completed Weather Pack termination for inspection or rework. The Weather Pack release tool depresses the terminal retention barbs and allows the Weather Pack terminals to be removed from the connectors.
How do I choose the right size cable seal?
The choice of cable seal is determined by the insulation diameter of the wire being used. The guidelines offered below apply to Weather Pack and Sealed Metri-Pack 280 Series installations.
F or Type GPT and GXL wire, the red seal normally fits 22 gauge; the green seal normally fits 20, 18, and 16 gauge; the gray seal normally fits 14 gauge; and the blue seal normally fits 12 gauge.
For heavier wall Type SXL wire, the green seal normally fits 20 and 18 gauge; the gray seal normally fits 16 gauge; and the blue seal normally fits 14 and 12 gauge.
For thin-wall wire construction such as Type TXL, the red seal normally fits 20 gauge; the green seal normally fits 18, 16 and 14 gauge; the gray seal normally fits 12 gauge; and the blue seal normally fits 10 gauge.
The installer must be certain that the seal fits snugly over the wire insulation to maintain a proper environmental seal.
This sounds rather complicated, is there a simpler way?
I you just need to repair an existing weather pack connection, consider getting a 'pigtail'. This consists of a pre-built connector with wires already attached. You simply need to use butt connector terminals to splice it into your application. You can find them HERE. We suggest using Heat Shrink Terminals to maintain the sealed electrical system.
What is the maximum current rating for Weather Pack connectors?
Delphi Packard Electric Systems rates Weather Pack at 0 - 20 amps maximum.
Why is Weather Pack available in 12-gauge if the maximum current rating is only 20 amps?
The 12-gauge Weather Pack terminals are designed for signal voltages where conductor reliability is critical. A larger conductor will provide a clearer signal than a smaller one. The 12-gauge Weather Pack terminals should not be used in high-current applications that would normally use 12-gauge wire.
Is there a sealed connection system that will carry more than Weather Pack's 20 amps?
Consider our Deutsch connector kits for applications over 20 amps.
Why are there slits on some of the individual towers on Weather Pack tower connectors?
The slits are called indexing slots and they prevent mismating. A Weather Pack tower connector will only fit the matching Weather Pack shroud connector.
What do the Weather Pack tower connector colors signify?
Colors are used with application-specific Weather Pack connectors to make them look different from the standard tower connectors. The colored connectors are designed to fit devices such as switches or sensors. They feature special indexing and are not interchangeable with the standard black tower connectors.
I’m looking for Weather Packs with flat male blade terminals or square profile female terminals. Do you have them?
The Weather Pack system uses only round pin terminals or round socket terminals. If a sealed connector without round terminals is marked "DELPHI" or "P.E.D.," it could be a Metri-Pack, a GT or a Ducon series connector.
My sample is marked ">PA 66< 96". Do you stock this part?
This marking identifies the connector material Polyamide 6/6 (a.k.a. Nylon) and the mold cavity number. This is not enough information to identify a component. Delphi/Packard Electric Systems' part numbers are typically 8 digits such as "12124582."
Is there a simple way to repair a Weather Pack Connection? Yes, consider using a pigtail assembly, like the ones we offer HERE. Simply splice this in place of your current connector. We suggest using Crimp & Solder Seal butt connectors to maintain the sealed connection.
Do I need a crimp tool made specifically for Weather Pack?
Not necessarily. Many open barrel crimp tools can perform an acceptable Weather Pack wire crimp. A Weather Pack seal crimp can be made with common slip joint pliers. Note that the seal crimp should be just firm enough to hold the seal in place. A tight seal crimp can damage the seal. Professional tools made specifically for Weather Packs crimp both the terminal and the seal in one cycle.
What does a proper Weather Pack crimp look like?