IK0800269 - Proper Wire Repair

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IK0800269
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Revision: 9
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ELECTRICAL SYSTEM
Created: 3/22/2011
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7/19/2018
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Title : Proper Wire Repair
Applies To : All vehicles

Change Log
Please refer to the change log text box below for recent changes to this article:
07/19/2018 ‐ Added part number for abrasion resistant tape.
08/09/2016 ‐ Added tool information. Updated formatting.
07/25/2016 ‐ Added change log. Updated authort for feedback purposes.

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Description
When wires and harness are allowed to rub against other objects that wear through the harness wrap and
individual wire insulation, the copper conductors are exposed and can result in shorting and corrosion
issues. This iKNow document illustrates the proper procedure for repairing those worn harnesses and wires.
In some cases the corrosion is significant enough to prevent the proper adhesion of solder to the wire
strands; in those cases replacement of that circuit will be necessary.

Procedure

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IK0800269 - Proper Wire Repair

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When repairing the abraded wire performing the following steps will prevent shorts and moisture entry into
the wire conductors:
1. Inspect the suspect harness for signs of wear against sharp and/or hard surfaces. It may be necessary
to power wash the harness and surrounding area to clean off accumulations of salt and road grime.
2. Determine the extent of damage to the individual wires within the harness. If the damage is to a
minimal number of individual conductors and the insulation is not completely worn through and there
is no copper exposed, the conductors and harness can be repaired by wrapping the individual wires
and harness with a good grade of electrical tape sufficient to restore the insulating qualities to the
original quality. Once the harness is repaired it must be rerouted to prevent further damage.
3. If the wear is sufficient to expose the copper conductors, the individual wires must either be cut and
spliced. If the individual conductors can be repaired by splicing, proceed with Step 4.
4. If the area where the copper conductors are exposed is less than 1" long and the conductors are not
badly frayed and cut. The wire can be repaired by cutting the wire in the middle of the damaged area,
stripping the insulation back on either side of the cut and applying a crimp splice, soldering, and
applying dual heat shrink tubing as described below:
i. Cut the conductor in the middle of the exposed conductor area.
ii. Strip the insulation back 1/4" from the wire ends as shown in Figure 1.
iii. Place a 2" piece of double wall heat shrink tubing on one of the wires to be spliced.
Figure 1

If the insulation is striped as shown in Figure 1 and the exposed wires are black from moisture
intrusion or green from corrosion, the technician should try to tin the wires before inserting them
into the crimp splice. If the wires tin properly and solder flows smoothly on to all the individual
wire strands the repair will be effective. If however, the solder does not flow properly and there is
evidence that all or parts of the conductor will not take solder, the wires should be cut father
back until wires appear to be clean, the insulation stripped again, and tinned again. If the wire
strands still won't take solder, the circuit should be replaced because the crimp splice will NOT be
effective.
iv. Crimp both wire ends into the appropriate sized crimp splice as shown in Figure 2. Make sure all
the individual wire strands are inside the crimp splice.
Figure 2

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IK0800269 - Proper Wire Repair

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v. Solder (60/40 rosin core) both conductors into the crimp splice. Make certain that the solder and
conductor are hot enough to allow the solder to "flow" into the individual conductors of the wire
and the inside of the crimp splice as shown in Figure 3.

A good solder joint is created by applying heat to the crimp splice, not to the wire conductors or
the solder. Once the splice is hot enough to melt the solder on contact, the solder will flow over
and into the crimp connector as well as flow into the individual strands of the wire. If the solder
joint is shiny and smooth then the proper temperature was obtained. If the solder is dull then the
operation has produced a "cold solder joint" and it should be reheated until the solder flows
properly.
Figure 3

vi. Slide the 2" section of double wall heat shrink tubing over the crimp splice and apply sufficient
heat to shrink the tubing over the connector and wires as show in Figure 4.
Figure 4

5. If abrasion is a concern in the harness, the harness can be wrapped with abrasion resistant tape
(7096462C1) under the nylon conduit.

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Service Parts Information
Part
Number

Description

Qty
per
Pkg

3517501C1 10‐12 AWG Splice

2

3517502C1 14‐16 AWG Splice

7

3517503C1 18‐22 AWG Splice

2

2644000R1

Dual Wall Heat Shrink,
50mm

50

7096462C1

Tape, Electrical Harness
(Abrasion Resistant)

1

Image

Special Tools
Tool Description

Tool
Number

Comments

Image

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IK0800269 - Proper Wire Repair

Indenter or Confined
Crimp Tool for Closed
Barrel Terminals

Hide Details

May be in
ZTSE 4282

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*Or Obtain
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