This 2006 Chevrolet Silverado came in with the complaint that the driver’s temperature door would shift between heat and a/c without the controls being adjusted. The actuator had been replaced with a quality ACDelco part. Testing found that the actuator counts on the scan tool would fluctuate when the actuator harness was wiggled around slightly.
There are two options for repairing this problem. First the connector can be replaced. The next option is to carefully disassemble the connector and tighten the terminals. First the red locking comb has to be removed. a small screwdriver can be used to release the clip.
There is a special square tipped terminal tool for releasing the locking tab on the terminal. The end of a large paper clip could also work.
Once the locking tab is compressed and released the wire and terminal can be pulled from the connector body.
One of the first things I try to do once the terminal has been removed is to reposition the locking tab as shown below.
In the next picture I point to the location where the metal need to be pushed in towards the center of the terminal. This needs to be done on all four sides.
These are of course brand new terminals. If you are like me and do this for a living having these around to perform drag tests saves a lot of time.
The re formed terminal ready to go back into the harness connector.
I want to point out that when this condition occurs it is almost always caused by human interference. Some one brutishly handling the connector while replacing a part or a cover being missing and the connector repeatedly being moved.