Sumitomo 8100-3617 TS 025 Sealed Series Male Terminal

The Component: Genuine Sumitomo 8100-3617 automotive sealed male pin crimp terminal contact. TS 025 / 0.64mm nominal tab width classification / Precision-formed high-conductivity brass / Tin-plated finish / Reel Form & Loose Piece strip tracking / Component Alias Code: 81003617 / Global Order Reference: 8100-3617.

Applications & Fitment: Engineered as a high-density, factory original equipment (OE) micro-terminal link for modern automotive wiring harnesses. This 025-size male pin terminal is a standard harness staple across major Japanese vehicle architectures—including comprehensive deployment across Toyota, Lexus, Nissan, and Honda electronic control networks. It serves as the definitive crimp pin replacement inside high-vibration sensor plugs, electronic throttle bodies, accelerator pedal position modules, and compact engine management links.

Sized perfectly to deliver an exceptionally stable electrical path within waterproof or non-waterproof housings, it forms a secure connection across low-current logic-level lines. Highly vulnerable to tab neck bending, core wing splitting, or latch tang damage if field technicians attempt crimping using generic un-profiled hand tools rather than specialized micro-automotive die sets, or if terminal extractions are forced blindly without releasing the internal locking tang.

Technical Attributes:

- Manufacturer Part Number: 8100-3617 / 81003617 (Brand: Sumitomo Wiring Systems / Genuine Factory Automotive Class)

- Product Series Taxonomy: TS 025 Sealed Series Interconnect System Family

- Component Typology: Male Tab Crimp Terminal Contact Pin

- Terminal Blade Dimension: 0.64mm (.025 inch) Nominal Width and Thickness Matrix

- Base Structural Compound: High-conductivity premium engineering brass alloy for superior elastic threshold performance

- Surface Treatment / Plating: High-durability Tin-Plated (Sn) coating for enhanced oxidation and corrosion resistance

- Environmental Application: Rated for Sealed applications (Utilizes independent wire cavity silicone seals to preserve complete isolation)

- Target Wire Section Profile: Precision optimized to accept conductor ranges from 0.22mm² up to 0.50mm² (Equivalent to 24 AWG down to 20 AWG automotive wire types)

- Electrical Performance Threshold: Reference continuous current handling up to 7.0 Amps (Subject to ambient temperature boundaries and core conductor selection)

- Low-Voltage Circuit Resistance: High-conductivity specification limited to an initial 8 milliohm Maximum path resistance

- Post-Testing Retention Resistance: Maximum 16 milliohm path boundary after extensive lifecycle and vibration durability stress tests

- Insulation Threshold Stability: Maintains a secure 100 Megohm Minimum isolation line at 500VDC to prevent cross-cavity tracking leakage

- Companion Mating Terminal: Links perfectly with matching TS 025 series female receptacle sockets, specifically part number 8100-3455

- Gold-Plated Alternate Variant: For gold-plated terminal tracks, refer to factory alternative part number 8100-3708 (Toyota repair link 82998-24360 / 82998-24370)

- Commercial Access: Available as convenient trade repair strip bundles or loose bulk commercial reels for automated strip tooling. Tiered B2B wholesale trade volume pricing breaks apply instantly inside your basket for independent garages, loom remanufacturers, and trade auto-electrical stockists.