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8W - 01 - 10
TERMINAL (Continued)
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one–half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1–1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing 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 (Fig. 11).
Fig. 11 1 SPLICE BAND
1 - SPLICE BAND
8W-01 WIRING DIAGRAM INFORMATION
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 12).
1 - CRIMPING TOOL
(5) Solder the connection together using rosin core
type solder only (Fig. 13).
CAUTION: DO NOT USE ACID CORE SOLDER.
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
(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 (Fig. 14).
1 - SEALANT
2 - HEAT SHRINK TUBE
Fig. 12 2 CRIMPING TOOL
Fig. 13 3 SOLDER SPLICE
Fig. 14 4 HEAT SHRINK TUBE
VA
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