Electrical - Wiring, Soldering and Crimping repairs
TSB: 09-024/052000-2006 B-SERIES TRUCK 2001-2006 TRIBUTE - ELECTRICAL - WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIP
NOTE:
This bulletin replaces 09-017/03. Please update your records accordingly.
BULLETIN NOTE
This bulletin supersedes the previous bulletin 09-017/03, issued on 11/3/2003. The APPLICABLE MODEL(S) / VINS and REPAIR PROCEDURE have been revised.
APPLICABLE MODEL(S)/VINS
^ 2000-2006 B-Series Truck
^ 2001-2006 Tribute
DESCRIPTION
Wire harness repairs have been supported through the availability of complete harnesses and/or the availability of individual components - wire, terminal, splices, heat shrink. This bulletin includes service information detailing wire folding, soldering and crimping techniques.
REPAIR PROCEDURE 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 Service Bulletin or other Mazda publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses, they should be repaired using the solder and heat-shrink repair procedure specified in this Service Bulletin. The Mazda Terminal Repair Kit (49L0-88-0A0) 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 available thought MStore at http://www.mstore2000.com.
SERVICE TIPS
Refer to applicable model year wiring diagrams for circuit information.
TWISTED WIRE CIRCUIT REPAIR
1. The twisting should not be disrupted for more than 2" (51 mm). Twist the repaired wire in the same direction and with the same number of twists as the original wiring. Reapply shielding on any shielded circuits.
2. Stagger the repairs to minimize harness diameter and to maintain harness length.
3. Leads that will not be used must be sealed with dual will heat shrink tubing and stowed. Silicone must not be used.
4. Excess wire from the harness can be folded back on itself to maintain harness length.
5. Reapply any convoluted tubing and harness tape that was removed to make the repair.
SPLICING 16 AWG & SMALLER DIAMETER WIRES
1. Strip 1-1/2" (37.2 mm) of insulation from WIRE 1 and strip 3/4" (19.5 mm) of insulation from WIRE 2.
NOTE:
^ Take care not to nick or cut any of the wire strands.
^ Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off.
^ If more than 1 strand of wire is cut or nicked, cut off the end and re-strip the wire.
2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced.
3. Twist the wires together.
4. Solider the wires together.
NOTE:
^ Use only rosin core mildly activated (RMS) solder.
CAUTION:
^ DO NOT use acid core solder.
5. Bend WIRE 1 back in a straight line for sealing and inspect the solder joint.
NOTE:
^ Allow the harness to cool before moving the wires.
6. Position heat shrink tubing evenly over the wire repair. Make sure the tubing overlaps both wires.
7. 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.
NOTE:
^ 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 joint.
SPLICING 14 AWG & LARGER DIAMETER WIRES (EXCLUDING RESTRAINT WIRING
REPAIRS)
1. Strip 1/4" (6.35 mm) of insulation from pigtail wire after sizing and staggering the wires.
NOTE:
^ Take care not to nick or cut any of the wire strands.
^ Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off.
^ If more than 1 strand of wire is cut or nicked, cut off the end and re-strip the wire.
NOTE:
^ The strip length will vary depending on the butt splice and wire gauge in harness. Longer strip lengths are required when the wire must be folded to mate with the butt splice. Refer to the following table and figure for strip lengths and folding techniques.
2. Slide heat shrink tubing onto 1 of the wire ends to be crimped, at least 1" (25.4 mm) away from the stripped end being spliced.
3. Using wire crimpers, identify the appropriate crimping chamber by matching the wire size on the dies with the wire size stamped on the butt splice.
4. Center 1 end of the butt splice in the crimping tool. If visible, place the brazed seam of the butt splice toward the indenter.
5. Preparing the wires and butt connector for crimping:
a. Hold the butt splice in position in the jaws of the crimper, squeeze until ratchet engages to hold the butt splice, but do not squeeze hard enough to deform the butt splice.
b. Insert the stripped wire into the butt splice, make sure the insulation on the wire does not enter the butt splice.
c. While holding the wire in place, squeeze the crimper handles together until ratchet releases. Allow handles to open, then remove crimped butt splice.
d. Repeat the steps above for the other half of the butt splice.
NOTE:
If splice cannot be turned for crimping the other half, turn the crimper around.
6. Verify acceptable crimp:
a. Crimp must be centered on each end of the butt splice.
b. Wire insulation must not enter butt splice. Wire is flush with or extends slightly beyond the end of the butt splice.
c. Wire is visible through the inspection hole of the butt connector.
7. Position heat shrink tubing over the wire repair.
NOTE:
^ Overlap tubing on both wires.
8. 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 joint.
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