Service Tips

Refer to applicable model year wiring diagrams for circuit information.

Twisted Wire Circuits





For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits.





Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2).

Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used.

Excess wire from the harness can be folded back on itself to maintain the harness length.

Reapply any convolute and tape that was removed to make the repair.

For 16 AGW and Smaller Diameter Wire





1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip.





2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4).

NOTE
USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR.

3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond.

NOTE
WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES.





4. Evenly position heat shrink tubing over wire repair (Figure 5).

NOTE
OVERLAP TUBING ON BOTH WIRES.

5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5).

For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs)

1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip.





NOTE
THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES.





2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6).





3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully.





4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8).

5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice.

6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8).

7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice.

8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around.

9. Check for acceptable crimp.





a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a).

b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b).

c. Wire is visible through inspection hole of splices (Figure 9-c).

10. Evenly position heat shrink tubing over wire repair (Figure 5).

NOTE
OVERLAP TUBING ON BOTH WIRES.

11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5).