Aptiv Weather-Pack Connectors, Custom Wire Harness Manufacturer

Aptiv Weather-Pack Connectors

Aptiv Weather Pack Connectors are robust, environmentally sealed electrical connectors engineered to endure harsh conditions, including extreme temperatures, moisture, and exposure to various chemicals and fluids. Featuring tin-plated terminals, these connectors utilize a crimp-only connection method, eliminating the need for soldering, thanks to specially designed core wings. The connector and cavity seals are triple-ribbed and crafted from self-lubricating silicone, ensuring a reliable seal against contaminants. Cavity plugs are also available to secure unused cavities, maintaining the integrity of the system. The connectors feature a pin-and-sleeve configuration to minimize stress relaxation, secondary locking mechanisms, and Connector Position Assurance (CPA) to enhance system reliability. Additional attributes include dual-locking tangs to prevent terminal back-out, a design that requires no specific orientation for terminal insertion, and positive locking to prevent mismating. With capabilities for low-energy, low-voltage vehicle electronics, these connectors offer a dependable solution for a variety of automotive applications.

Weather-Pack Connector Features

• Connector position assurance (CPA) is available
• Secondary lock (cover)
• 20A continuous maximum current rating
• Sealed system
• Pin and sleeve configuration
• Dual-locking tangs on terminals
• Low energy, low voltage capability
• -40°C to +125°C operating temperature range

Weather-Pack Connector Specifications Chart

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Support Custom Wire Harness Assembly

• Connectors: 1P to 22P.
• Wire Gauge: 
  • depends on your needs
  • recommend by us
• Wire Colors: Available in a wide range including white, black, red, yellow, blue, green, brown, orange, purple, grey, and more.
• Wire Length: Fully customizable to your specifications.
• Wiring Diagram: Tailor-made to meet your project needs.
• Custom type:
  • Send drawing to customize.
  • Send a sample to customize.
  • Tell us as many details as possible to customize.
• Minimum Order: 50 pieces per order.

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Customize Your Wire Harness

Send your sample or drawing/schematic for quote price→ Feedback with quotation(1~3 days) → Confirm quotation → Arrange sample you for approval→ [Make mold if needed (7 days) →Mold test] → Making samples(1~3 days)→ Samples test(Approval) → place order for Mass production(2~3 weeks)→ Quality checking→ Packing → Delivery → After Service → Repeat Order.

Frequently Asked Questions

1. How to Differentiate from Other Common Automotive Connectors?

It's easy to confuse Weather Pack with other sealed connectors. Here’s a quick guide:

2. Can I use Weather Pack connectors on automotive wiring?

Yes, Weather Pack connectors are an excellent choice for automotive wiring. Originally developed by GM, they are designed for harsh under-hood environments.

Their key advantage is a sealed design: each terminal has a silicone seal that makes the connection waterproof and resistant to dirt, chemicals, and road salt. The terminals are also corrosion-resistant and provide a firm, vibration-proof crimp.

The crucial requirement is using the proper Weather Pack crimping tool. Standard crimpers cannot correctly form the dual crimps for the wire and insulation seal. A proper tool is essential for a reliable, long-lasting connection.

They are ideal for engine sensors, lights, and any wiring exposed to moisture or elements.

3. How many amps can a Weather Pack connector handle?

The amperage rating of a Weather Pack connector depends on the terminal size, not the plastic housing itself.

The standard terminal sizes and their approximate continuous current ratings are:

• ​​12-10 Gauge Terminals:​​ 25 amps
• ​​14-16 Gauge Terminals:​​ 13 amps
• 18-20 Gauge Terminals:​​ 7 amps

These ratings are based on a maximum temperature rise of 20°C at 13.5 volts. For high-vibration environments or applications with significant voltage drop, it is prudent to derate these values for a safety margin. Always ensure a proper crimp with the correct tool to maintain the connector's rated performance.

4. What's the difference between Weather Pack & Metri-Pack?

Weather Pack and Metri-Pack are both sealed automotive connector systems from the same manufacturer (Aptiv, formerly Delphi). The key differences are in their design and application:

​​Weather Pack:​​ The older, more common standard. It uses large, round silicone seals for each terminal and has a simple, audible snap-latch. It's bulkier and generally rated for lower current applications (typically up to 25A).

​​Metri-Pack:​​ The newer, more advanced generation. It uses a more compact, rectangular seal and a complex, high-retention CPA (Connector Position Assurance) latch for a more secure connection. It is smaller, handles higher vibration, and includes features like TPA (Terminal Position Assurance) to prevent incorrect assembly. Metri-Pack terminals are not interchangeable with Weather Pack.

In short, Metri-Pack is a more sophisticated, compact, and secure evolution of the sealed connector design, often used in more critical modern automotive applications.