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Article No.
01-10-12 |
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WIRING - WIRE HARNESS TERMINAL REPAIR KIT AND WIRE SPLICE
PROCEDURE
|
| Publication Date: MAY 21,
2001 |
| FORD: |
1985-94 TEMPO
1985-97 THUNDERBIRD
1985-2002 CROWN VICTORIA, ESCORT, MUSTANG
1986-2002 TAURUS
1988-93 FESTIVA
1993-97 PROBE
1994-97 ASPIRE
1995-2000 CONTOUR
2000-2002 ESCORT ZX2, FOCUS
2002 THUNDERBIRD |
| |
1985-90 BRONCO II
1985-96 BRONCO
1985-97 F-250 HD, F-350
1985-2002 ECONOLINE, F-150, RANGER
1986-97 AEROSTAR
1988-97 F SUPER DUTY
1991-2002 EXPLORER
1995-2002 WINDSTAR
1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION
2001-2002 EXCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT |
| |
1985-99 F & B SERIES
1999-2002 F-650, F-750
|
| LINCOLN: |
1985-92 MARK VII
1985-2002 CONTINENTAL, TOWN CAR
1993-98 MARK VIII
2000-2002 LS |
| |
1998-2002 NAVIGATOR
|
| MERCURY: |
1985-94 TOPAZ
1985-97 COUGAR
1985-2002 GRAND MARQUIS
1986-2002 SABLE
1991-99 TRACER
1991-94 CAPRI
1995-2000 MYSTIQUE
1999-2002 COUGAR |
| |
1993-2002 VILLAGER
1997-2002 MOUNTAINEER |
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.
- 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.
- 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.
- Form (bend) the circuit into a shape for
sealing ( Figure 3 ).
- 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. |
- 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
Figure 1 - Article 01-10-12
Figure 2 - Article 01-10-12
Figure 3 - Article 01-10-12
Figure 4 - Article 01-10-12
Figure 5 - Article 01-10-12
Figure 6 - Article 01-10-12
Figure 7 - Article 01-10-12
Figure 8 - Article 01-10-12
Figure 9 - Article 01-10-12
Figure 10 - Article 01-10-12
Figure 11 - Article 01-10-12
