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8W-01- 1 0
SERVICE PROCEDURES (Continued)
(12)
Solder the connection together using rosin
core type solder only . Do not use acid core solder.
(13)
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
(14) Repeat steps 8 through 13 for each wire .
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair .
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems .
TERMINAL REPLACEMENT
(1)
Disconnect battery.
(2)
Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig . 21) .
(3)
Remove connector locking wedge, if required
(Fig . 21) .
CONNECTOR
CONNECTOR LOCKING
WEDGE TAB
928W-143
Fig. 21 Connector Locking Wedge Tab (Typical)
(4)
Position the connector locking finger away
from the terminal using the proper pick from special
tool kit 6680. Pull on the wire to remove the terminal
from the connector (Fig . 22) (Fig. 23) .
(5)
Cut the wire 6 inches from the back of the
connector.
(6) Remove 1 inch of insulation from the wire on
the harness side .
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired .
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation .
(9)
Place a piece of heat shrink tubing over one
side of the wire . Make sure the tubing will be long
enough to cover and seal the entire repair area .
(10) Spread the strands of the wire apart on each
part of the exposed wires .
(11)
Spread the strands of the wire apart on each
part of the exposed wires .
8W - 01 GENERAL INFORMATION
TJ
FROM
SPECIAL TOOL
KIT 6680
948W-236
Fig . 22 Terminal Removal
FROM
SPECIAL TOOL
KIT 6680
CONNECTOR
948W-237
Fig. 23 Terminal Removal Using Special Tool
(12) Push the two ends of wire together until the
strands of wire are close to the insulation .
(13) Twist the wires together.
(14)
Solder the connection together using rosin
core type solder only . Do not use acid core solder.
(15) 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 .
(16) Insert the repaired wire into the connector.
(17)
Install the
connector locking wedge,
if
required, and reconnect the connector to its mating
half/component .
(18) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair .
(19) Connect battery, and test all affected systems .
DIODE REPLACEMENT
(1)
Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
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Table of Contents
Troubleshooting
