Splicing Copper Wire Using Crimp and Seal Splice Sleeves

Crimp and seal splice sleeves may be used on all types of insulation except tefzel and coaxial to form a one-to-one splice. They are to be used where there are special requirements such as moisture sealing. Crimp and seal splice sleeves are included in the J 38125 terminal Repair Kit.

Step One: Open the Harness
If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing supply stores). The crimp and seal splice sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to form a one-to-one splice.

Step Two: Cut the Wire
Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1-1/2 in) away from other splices, hamess branches, or connectors. This will help prevent moisture from bridging adjacent splices and causing damage.

Wire Size Conversion Table:

Step Three: Strip the Insulation
If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire.

To find the correct wire size, either find the wire on the schematic page and convert the metric size to the equivalent AWG size or use an AWG gage. If unsure about the wire size, begin with the largest opening in your wire stripper and work down until you get a clean strip of the insulation. Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.

Crimp And Seal Splice Sleeve Chart:

Step Four: Select and Position the Splice Sleeve
Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color coded (refer to Chart).

Hand Crimp Tool:

Using the J 38125-8 splice crimp tool, position the splice sleeve in the proper color nest of the hand crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop.

Seal Splice Sequence:

The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest.

Step Five: Insert Wires into the Splice Sleeve and Crimp
Insert the wire into the splice sleeve until it hits the barrel stop, and close the handles of the J 38125-8 crimper tightly until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice.

Step Six: Shrink the Insulation around the Splice
Using a heat torch, apply heat where the barrel is crimped. Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.