Automotive Connector Terminal – 1241404-3 / DJ6234-6.3B, 6.3mm Female Crimp Contact

6.3mm female crimp terminals for high-current automotive wiring harness applications. Part number 1241404-3 is the TE Connectivity / AMP catalog number; DJ6234-6.3B is the Chinese standard equivalent. The 6.3mm pitch is the largest standard automotive terminal size, used for main power distribution, starter motor connections, alternator output connections, and high-current accessory circuits where the 2.8mm and 4.8mm series are insufficient. Current rating: 25–30A per contact.

Key Specifications

• Part Numbers: 1241404-3 (TE Connectivity/AMP), DJ6234-6.3B (Chinese standard)
• Contact Type: Female crimp terminal (socket contact)
• Pitch: 6.3mm
• Wire Range: 2.5–6.0mm² (14–10AWG)
• Current Rating: 25–30A per contact
• Contact Material: Copper alloy, tin-plated
• Application: Main power distribution, fuse box, and high-current circuit connections

6.3mm Terminal Applications in Automotive Wiring

• Main fuse box: High-current fuse connections (20–30A circuits) in the main fuse/relay box
• Alternator output: Alternator B+ terminal connections
• Starter motor: Starter solenoid and motor terminal connections
• Main power distribution: Battery-to-fuse-box and fuse-box-to-load connections for high-current circuits
• Electric motors: Window regulator, sunroof, and seat motor power connections
• Heating elements: Rear window demister and heated seat high-current connections

Frequently Asked Questions

What is the maximum current for 6.3mm terminals?

6.3mm terminals are rated at 25–30A per contact depending on the specific terminal design and wire gauge. For a 30A circuit at 12V: 30A × 12V = 360W. This covers most high-current automotive accessories. For currents above 30A (main battery cables, starter motor cables), use cable lugs (ring terminals) with bolted connections rather than crimp-in-housing terminals.

What crimp tool is required for 6.3mm terminals?

6.3mm terminals require a crimp tool with dies sized for the 6.3mm contact geometry and the wire gauge being used. TE Connectivity specifies the 91526-1 or equivalent crimp tool for 1241404-3 terminals. Using the wrong crimp tool produces an incomplete crimp that fails pull-out testing. For 6.3mm terminals with 4–6mm² wire, a heavy-duty ratchet crimp tool is required — standard light-duty crimp tools do not provide sufficient force.

How do I repair a burnt 6.3mm fuse box terminal?

Burnt 6.3mm fuse box terminals are caused by sustained overcurrent or high contact resistance. Repair: (1) identify and fix the root cause (replace the fuse with the correct rating, repair the circuit fault causing overcurrent); (2) extract the burnt terminal using a terminal extraction tool; (3) cut the wire behind the burnt terminal; (4) crimp a new 1241404-3 terminal onto the wire using the correct crimp tool; (5) insert the new terminal into the fuse box housing. If the housing cavity is melted, replace the fuse box housing.

Typical Applications

• Fuse box repair: High-current fuse box terminal replacement in European and Asian vehicles
• Power distribution: Main power circuit terminal replacement
• Alternator & starter: High-current terminal replacement at alternator and starter connections
• Automotive workshops: Workshop stock for high-current terminal repairs

Package Contents

Automotive crimp terminals (1241404-3 / DJ6234-6.3B, quantity as selected). Connector housing not included.