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Automotive Wiring Splice Methods
From TSB 08-05-00
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WIRE SPLICING METHOD 1

1 .    Remove one (1) inch of insulation from each wire that needs to be spliced.

2.    Place a piece of heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.

3.    Spread the strands of wire apart on each exposed portion of the wire that needs to be spliced (Figure 4 - Example 1).

4.     Push the two ends of the wires together until the strands of wire are close to the insulation (Figure 4 - Example 2).

5.     Twist the wires together (Figure 4 - Example 3).

 

6.     Solder the connection together using rosin core type solder only.

CAUTION:    DO NOT USE ACID CORE SOLDER.

7.     Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint I until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 5).

WIRE SPLICING METHOD 2

l.     Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.

2.     Place a piece of heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.

3.     Place the strands of wire overlapping each other inside of the splice clip (Figure 6).

4.     Using crimping tool 8272 or equivalent, crimp the splice clip and wires together (Figure 7).

5. Solder the connection together using rosin core type solder only (Figure 8).

 

CAUTION:    DO NOT USE ACID CORE SOLDER.

6.     Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 5).


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Last Update: March 3, 2000