Electrical - Wiring Soldering/Crimping Service Tips: Overview
TSB 05-18-709/22/05
WIRING - SOLDERING AND CRIMPING REPAIRS -
SERVICE TIPS
FORD:
2000-2006 Crown Victoria, Focus, Mustang, Taurus
2002-2005 Thunderbird
2005-2006 Five Hundred, Ford GT, Freestyle
2006 Fusion
2000-2003 Explorer Sport, Windstar
2000-2005 Excursion
2000-2006 E-Series, Expedition, Explorer,
F-150, F-Super Duty, Ranger
2001-2005 Explorer Sport Trac
2001-2006 Escape
2004-2006 Freestar
2005-2006 Escape Hybrid
2000-2006 F-650, F-750
2006 Low Cab Forward
LINCOLN:
2000-2006 LS, Town Car
2006 Zephyr
2000-2006 Navigator
2002-2003 Blackwood
2003-2005 Aviator
2006 Mark LT
MERCURY:
2000-2002 Cougar
2000-2005 Sable
2000-2006 Grand Marquis
2005-2006 Montego
2006 Milan
2000-2006 Mountaineer
2004-2006 Monterey
2005-2006 Mariner
2006 Mariner Hybrid
This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years.
ISSUE
Wire harness repairs are supported through the availability of individual components such as:
^ Wire terminals with machine crimped pigtails
^ Hard shell connectors
^ Dual wall heat shrink tubing
^ Complete, loaded, wiring pigtail kits
Some of the available tools and service parts that are helpful when performing wiring harness repairs are:
^ Motorcraft Wiring Pigtail Catalog (see website for more information)
^ Rotunda Wire Splice Tool kit 164-R5903
^ General Wire Terminal Repair Kit (order through Ford Component Sales)
Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS:
^ Select the year/model of the vehicle on the P15 home page
^ Select the wiring tab
^ Select the link to the pigtail or terminal repair kit at the top right of screen.
Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful.
ACTION
REPAIR VS REPLACEMENT
The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when:
^ The repair cost exceeds the cost to replace the wiring harness
^ There are no component parts released to service the wiring harness
RESTRAINTS RELATED WIRING REPAIRS
If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog.
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