Wiring - Soldering And Crimping Repairs - Service Tips (05-18-7)

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.

TWISTED WIRE CIRCUITS

For "Twisted Wire" circuit repair (Fig 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 (Fig 2 ).

Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Fig 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.

Fig 1: Twisted Type Wire

Fig 2: Staggered Wire Splices

FOR 16 AGW AND SMALLER DIAMETER WIRE

1. Strip 1 1/2" (37.2mm) of insulation from Wire #1 and 3/4" (19.5mm) of insulation from Wire #2, taking care not to nick or cut wire strands (Fig 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.
Fig 3: Proper/Improper Wire Stripping

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 (Fig 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 (Fig 4 ). Inspect solder joint bond.
   NOTE: WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES.
Fig 4: Splicing Wire - 16 AWG Smaller

4. Evenly position heat shrink tubing over wire repair (Fig 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 (Fig 5 ).
Fig 5: Shrink Tubing Position On Wire Splice

FOR 14 AGW AND LARGER DIAMETER WIRE

(EXCLUDING RESTRAINTS WIRING REPAIRS) 

1. Strip 1/4" (6.35mm) 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" (25.4mm) away from stripped end (Fig 6 ).
Fig 6: Proper/Improper Wire Stripping For Butt Splice

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 (Fig 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.
Fig 7: Crimping Chamber Identification On Crimping Tool

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 (Fig 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 butt splice, making sure the insulation on wire does not enter the butt splice (Fig 8 ).
Fig 8: Crimping Butt Splice Connector

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.
   1. 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 butt splice (Fig 9 -a).
   2. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of butt splice (Fig 9 -b).
   3. Wire is visible through inspection hole of splices (Fig 9 -c).
Fig 9: Finished Butt Splice

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

Fig 10: Strip Lengths & Folding Techniques