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Article No. 01-10-12	WIRING - WIRE HARNESS TERMINAL REPAIR KIT AND WIRE SPLICE PROCEDURE
Publication Date: MAY 21, 2001

This article is being republished in its entirety to update the model year coverage and parts supplier information.

ISSUE:

A wire harness terminal repair kit is available for repairing electrical wiring harnesses.  This kit allows the dealer to repair broken or corroded terminals instead of replacing an entire wiring harness.

ACTION:

If wiring repairs are required, dealers can obtain a kit by using the included Order Form (Figures 6-11).  Pricing information is included for the complete boxes and restocking merchandise for the individual dealers.

• U.S.A. - Ford Component Sales, LLC: Orders may be called in (877)682-4276.  Or Fax completed order sheet to (734)523-5920.
• Canada - Jobborn Manufacturing Limited: Orders my be called into (800)337-0823 or (905)336-6696.
• Mexico - Fax completed order sheet to (734)523-5920

SERVICE PROCEDURE

NOTE:

AN ULTRA-TORCH (SELF-IGNITING) IS AVAILABLE THROUGH ROTUNDA (107-R0304).  THE ULTRA-TORCH IS A CORDLESS SOLDERING IRON/HEAT GUN RECOMMENDED TO BE USED FOR SOLDERING, STEP 2, AND HEAT SHRINKING, STEP, PROCESSES.

Dual Wall Heat Shrink Tubing provided with Repair Kit Box #3 may be used for 16, 18, or 20 gauge wire only.  For wire gauges larger than 16, a Deutsch Jiffy Splice must be used (available in Repair Kit Box #1 and #2).

NOTE:

A HIGH COMPRESSION CRIMP TOOL MUST BE USED WITH THE DEUTSCH JIFFY SPLICES.  ROTUNDA DOES NOT OFFER A HIGH COMPRESSION CRIMP TOOL.

Dual Wall Heat Shrink Tubing containing hot melt wax is included with Repair Kit Box #3 and offers a Ford-approved method for joining two (2) circuits.  When properly used with a soldered circuit joint, the Ford-approved heat shrink tubing will provide a stable, low electrical resistance connection for years of service in any Ford or Lincoln-Mercury vehicle.

If an unreliable splicing method is used, the circuit joint may be unstable, resulting in variable resistance or a short circuit.  Variable resistance can be the result of oxidation (corrosion) caused by air within the joint.  A short circuit (signal leakage) is caused by either moisture on the circuit joint or a frayed wire coming in contact with another wire.  Either situation may cause electrical systems to malfunction.

It is important to use heat shrink tubing containing hot melt wax over a soldered circuit joint to create a waterproof and airtight connection.

The following five (5) Steps should be used when joining two (2) circuits using solder and heat shrink tubing containing hot melt wax.

1. Strip 38mm (1.5") of insulation from Wire #1 and 19mm (0.75") of insulation from Wire #2 ( Figure 1 ).  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 end and restrip.
2. Twist and solder the wires (do not forget to install the heat shrink tubing first) ( Figure 2 ).  Use rosin core mildly activated (RMA) solder.  DO NOT use acid core solder.
3. Form (bend) the circuit into a shape for sealing ( Figure 3 ).
4. Reposition heat shrink tubing over splice ( Figure 4 ).

   NOTE:

   DURABILITY OF HEAT SHRINK TUBING SPLICE IS DEPENDENT ON THE HOT MELT WAX THAT WILL APPEAR FROM BOTH ENDS OF THE TUBE.  THE HOT MELT WAX FORMS AN ADHESIVE SEAL BETWEEN THE WIRE INSULATION AND THE HEAT SHRINK TUBING WHICH PREVENTS AIR AND MOISTURE FROM ENTERING THE SOLDER POINT.

5. Heat the entire length of the heat shrink tubing until the hot melt was appears from both ends of the tubing ( Figure 5 ).

OTHER APPLICABLE ARTICLES:

NONE

SUPERCEDES:

99-22-02

WARRANTY STATUS:

INFORMATION ONLY

OASIS CODES:

203000, 203200, 205000, 290000

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