SIR Wire Repair

TOOL REQUIRED

J 38125-A Terminal Repair Kit
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5, 0.8, 1.0, etc.). Use the sealed splices and splice crimping tool from Terminal Repair Kit J 38125-A for these repairs. Use the following WIRING repair procedures to ensure the integrity of the sealed splice.

1. Open the harness by removing the tape.
^ To avoid wire insulation damage use a sewing "seam ripper" (available from sewing supply stores) to cut open the harness.
^ Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial.
^ Do not use the crimp and sealed splice sleeve to form a splice with more than two wires coming together.
2. cut the wire.
^ Cut as little wire off the harness as possible. You may need the extra length of wire to change the location of a splice.
^ Adjust splice locations so that each splice is at least 40 mm (1.5 inch) away from other splices, harness branches, or connectors.

NOTICE: Follow these procedures in the order listed. If the wire strands are damaged, repeat the procedure until a clean strip with all wire strands intact is obtained.

3. Strip the insulation
^ When adding a length of wire to the existing harness, be certain to use the same size wire as the original wire.
^ To find the correct wire size do one of the following:
^ Find the wire on the schematic and convert the metric size to the equivalent AWG size.
^ Use an AWG wire gage.
^ If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.
4. Strip approximately 7.5 mm (0.313 inches) of insulation from each wire to be spliced.
^ Be careful to avoid nicking or cutting any of the strands. Check the stripped wire for nicks or cut strands.
^ If the wire is damaged, repeat Step Four after removing the damaged section.
5. Select the splice sleeve.
^ Select the proper sealed splice sleeve according to wire size.
^ The splice sleeves and tool nests are color coded (see following chart).