Replacing a wire in a wiring harness typically involves repairing a break in the wire, and the method depends on where the break occurs.
When addressing a broken wire within a wiring harness, the repair technique is dictated by the location of the damage – whether the wire is broken at the connector or somewhere along its length in the middle.
Replacing a Wire Broken at a Connector
If a wire breaks right at its connection point to a terminal within a connector housing, the process focuses on replacing the damaged end. According to common practice referenced in the provided text, when wires are broken at a connector, you simply strip the ends and crimp on new connectors.
This method involves:
- Carefully removing the old, broken wire and terminal from the connector housing.
- Stripping a short length of insulation from the end of the wire.
- Crimping a new terminal onto the freshly stripped wire end using the appropriate crimping tool for the specific terminal type.
- Inserting the new terminal with the attached wire back into the correct location in the connector housing.
Replacing a Wire Broken in the Middle
When a wire is broken or damaged along its span, away from a connector, it requires splicing to rejoin the two ends or insert a new segment. The reference states, when they're broken in the middle like this, they need to be spliced.
Splicing involves joining the two wire ends securely and safely. The text mentions several methods for splicing:
- Using crimp-on butt-splice connectors: These are tubular connectors where each wire end is inserted into an opening and then crimped down to create a mechanical and electrical connection. Insulated and heat-shrink varieties are available.
- Using heat-shrink solder-splice connectors: These connectors contain a ring of solder and a heat-shrinkable sleeve. The wire ends are inserted into the sleeve, centered over the solder ring, and heat is applied. The heat melts the solder to join the wires and shrinks the sleeve to insulate and seal the splice.
- Soldering the wires manually: This traditional method involves stripping the wire ends, twisting them together, and then applying solder to create a strong electrical connection. The joint must then be insulated, typically using heat-shrink tubing or electrical tape.
Choosing the best splicing method often depends on factors like the wire gauge, the location of the splice (e.g., engine bay vs. interior), and the tools available. Heat-shrink solder-splice connectors are often favored for their convenience and weather-resistant properties in demanding environments.
Regardless of the method used, ensuring a clean, secure, and properly insulated connection is crucial for the reliability and safety of the wiring harness.
