Yazaki Automotive Connector Terminal – 8240-0545 / 8240-0546 / 8240-0547 / 8240-0548, Crimp Contact for Toyota & Ford Wiring Harness

Yazaki automotive crimp terminals — part numbers 8240-0545, 8240-0546, 8240-0547, and 8240-0548 are variants within the same Yazaki 8240-XXXX terminal series, differing in contact gender, wire gauge range, or plating. Yazaki is one of the world’s largest automotive connector and wiring harness manufacturers, supplying Toyota, Ford, Mazda, Honda, and other major OEMs. These loose terminals are used for wiring harness repair, replacing damaged contacts in existing Yazaki connector housings.

Part Number Variants

• 8240-0545: Specific contact gender, wire range, and plating — verify against your application
• 8240-0546: Variant — may differ in wire gauge range or contact geometry
• 8240-0547: Variant — may differ in plating (tin vs gold) or contact geometry
• 8240-0548: Variant — verify against the original terminal and connector housing
• Cross-reference each part number in the Yazaki catalog to identify the specific contact specifications before ordering.

Key Specifications

• Manufacturer: Yazaki
• Part Numbers: 8240-0545 / 8240-0546 / 8240-0547 / 8240-0548
• Contact Type: Crimp terminal (male pin or female socket — verify by part number)
• Contact Material: Copper alloy, tin or gold-plated
• Application: Yazaki connector housings in Toyota, Ford, and other OEM vehicles

Frequently Asked Questions

How do I identify which 8240-XXXX variant I need?

Cross-reference the original terminal part number (stamped on the terminal or listed in the vehicle’s wiring diagram) with the Yazaki catalog. The 8240-XXXX suffix distinguishes: (1) contact gender (male pin vs female socket); (2) wire gauge range (different suffixes cover different AWG ranges); (3) plating (tin vs gold). If the original terminal part number is not visible, identify the connector housing part number and cross-reference to find the compatible terminal variants.

What crimp tool is required for Yazaki 8240-series terminals?

Yazaki specifies a dedicated crimp tool for each terminal series. Cross-reference the terminal part number in the Yazaki catalog to identify the required crimp tool. Using the wrong crimp tool produces an incomplete crimp that fails Yazaki’s pull-out force specification. For professional Toyota/Ford harness repair, use the Yazaki-specified ratchet crimp tool with the correct die.

Can I use these terminals to repair a Toyota or Ford connector?

Yes. Repair procedure: (1) use a Yazaki-compatible terminal extraction tool to remove the damaged terminal; (2) cut the wire behind the damaged terminal; (3) strip the wire to the correct length per the Yazaki datasheet; (4) crimp the new terminal using the correct Yazaki crimp tool; (5) insert until the locking lance clicks; (6) verify seating with a pull-test.

Typical Applications

• Toyota vehicles: Terminal replacement in Yazaki connector housings throughout the vehicle
• Ford vehicles: Yazaki terminal replacement in Ford/Mazda platform wiring harnesses
• Automotive workshops: Workshop stock for Toyota/Ford terminal repairs
• Harness manufacturing: Loose terminals for custom harness builds using Yazaki housings

Package Contents

Yazaki automotive crimp terminals (part number as selected: 8240-0545 / 8240-0546 / 8240-0547 / 8240-0548, quantity as selected). Connector housing not included.