Splicing Wire

1. Open the Harness
If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing seam ripper" (available from sewing supply stores) to cut open the harness.
If the harness has a black plastic conduit, simply pull out the desired wire.
2. 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 off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 1-1/2" (40 mm) away from other splices, harness branches, or connectors.
3. Strip the Insulation
When replacing a wire, use a wire of the same size as the original wire. Check the stripped wire for nicks or cut stands. If the wire is damaged, repeat the procedure on a new section of wire. The two stripped wire ends should be equal in length.




4. Crimp the Wires
Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included with your clips. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the two stripped wire ends and hold them between your thumb and forefinger. Then, center the splice clip under the stripped wires and hold it in place.
- Open the crimping tool to its full width and rest one handle on a firm flat surface.
- Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the back of the splice clip touches the wings of the clip.




- Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes.

Before crimping the ends of the clip, be sure that:
- The wires extend beyond the clip in each direction.
- No strands of wire are cut loose, and
- No insulation is caught under the clip.




Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires.




5. Solder
Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment you are using.




6. Tape the Splice
Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends wilt tangle with the other wires in the harness.




If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape.