Folded-Over Wire Repair

Folded-Over Wire Repair

Special Tools

EL-38125-10 - Splice Sleeve Crimping Tool

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

The GM global wire repair strategy uses connector assemblies (pigtails) and terminated leads to repair wiring harnesses.

To reduce and manage GM Service Parts proliferation, the service pigtails and terminated leads are designed with the largest wire gauge size that can be held by either the terminal or the connector housing.

The folded over wire repair technique, in which the copper wire strands are folded over before being installed into a splice sleeve, allows the service part to be used when repairing a smaller gauge size wire in a vehicle. This technique has passed all GM testing standards.





Use the folded over wire repair for:

Note: Increasing the amount of copper strands in the smaller gauge size will allow for a better crimp

* Splicing wires of 0.35 mm or less (22, 24 26 gauge sizes)

Note: Vehicle side needs to be of same or less gauge size (not greater than the service part's gauge size)

* Splicing wires of different gauges

Use the Service Information (SI) connector end-views to determine:

* Gauge size of wiring harness
* Recommended Repair: Terminated Lead or Pigtail

The following table lists the acceptable variance within the gauge size





Example

For an IP Harness of 0.22 mm (24 gauge) wire size, the SI connector end-view recommends a pigtail with leads of 18 (0.8 mm) with a salmon colored DuraSeal splice sleeve of 0.5-1.0 mm (20-16).





Note: Example with 24 gauge harness and 18 gauge pigtail.

Follow these steps to use the folded over wire technique on an IP Harness.




1. Strip twice the amount of insulation on the smaller (1) wire (IP Harness is the lower wire) than normally required. Normally, the terminated leads have 5 mm of insulation stripped off the wire.




Note: Use splice sleeve crimping tool J-38125-10.




2. Twist the wires before you fold them over to prevent the wire strands from opening up. Fold over the copper wire strands of the smaller (1) gauge wire so that it is the same length as the non-folded wire.




3. Insert the folded over wire (1) into the splice sleeve.




4. Use the proper crimp tool to crimp the splice sleeve to the smaller wire (harness side of repair). Complete the crimp as usual (using the heat tool to shrink the tube).