Section XXIII. WIRE LEADS AND WIRING HARNESSES
5.118. Repair Methods
Preferred repair methods consist of replacing wires, terminals, connectors, etc. rather than splicing wires, bending ends to
form terminals, and other make-shift procedures, although the latter maybe appropriate for emergency field repairs.
Determine the proper size and length of wire, terminal or connector to be used for replacement by referring to Table 5-3,
Wire List, and to the wiring diagram (figure FO-1).
a. Soldering Connections. Wire
be made mechanically
sound before they are
alone does not provide sufficient strength to prevent breakage. Joining surfaces of connections to be soldered must be
clean and bright. If a separate flux is used, it should conform to Specification MIL-F-4995, Type I, rosin-alcohol flux,
and should be brushed onto the joint before soldering. If a flux-core solder is used, it should always be rosin-core
electrical solder. If an uncored solder is used, it should be a lead-tin solder conforming to Specification QQ-S-571.
Wires should always be heated to the point at which the solder will melt completely and flow into all parts of the joint.
Excessive build-up of solder "gobs" on the joint should be avoided or removed.
b. lnsulating Joints. The preferred method of insulating electrical joints is by the use of heat-shrink tubing. To
apply, cut a piece of heat-shrink tubing of suitable diameter to a one-inch length for covering joints at terminals or
connectors, or to a length about 1/2-inch longer than the joint to be insulated, and slide the tubing over the wire before
making the joint. After the joint is made, slide the tubing over the joint, and shrink in place with moderate heat.
c. Spiking Wires. To repair broken or cut wires that are otherwise sound. the mating ends can be stripped and
spliced. A commercial butt splice can be crimped onto the ends to joint them, or a "Western Union" wire splice can be
made. The latter is made by stripping one 1-1/4 inch of insulation from the wire ends, holding the ends parallel and facing
opposite directions, then twisting each end around the other wire at least three turns. Solder and apply insulation as
d. Crimping Terminals. To install a terminal on the end of a wire, strip 1/4-1/2 inch of insulation f rom the end of
the wire, apply a one-inch piece of heat-shrink tubing (if the terminals are of the uninsulated type), and insert wire-end
into the shank of the terminal. Crimp the shank, and install heat-shrink tubing if necessary.
Wiring Harness - Control Module