Communication Circuit Wiring Repair

The following procedure is to be used to service both the twisted pair wiring and single wire communication circuits. Durability of a wire splice is dependent on getting a joint that does not oxidize. Soldering is effective in keeping the air (oxide) out of the joint electronic circuits. Very high current circuits may fail because of oxidized joints that are not visible with the naked eye.

Durability of a splice is also dependent on keeping the moisture out of the joint. Heat shrink tubing alone won't do it. The tubing must contain a "hot melt wax" which is squeezed from the ends (both ends) of the tubing during heating and forms an adhesive seal between the wire insulation and the tube.

1. Correctly strip the wire. See Fig 1 .
2. Twist and solder the wire. See Fig 2 . Use Resin core Mildly Activated (RMA) solder. Do not use acid core solder.
3. Form (bend) the circuit into shape for sealing. See Fig 3 .
4. Reposition shrink tubing over splice. See Fig 4 .
5. Using Rotunda Heat Gun (107-R0301) or equivalent, heat the entire length of the shrink tubing until the hot wax comes out of both ends. See Fig 5 . When the hot wax flows out of both ends, remove heat.

Fig 1: Stripping Wire

Courtesy of FORD MOTOR CO.

Fig 2: Soldering Wire Connection

Courtesy of FORD MOTOR CO.

Fig 3: Bending Circuit Into Shape For Sealing

Courtesy of FORD MOTOR CO.

Fig 4: Positioning Shrink Tubing Over Splice

Courtesy of FORD MOTOR CO.

Fig 5: Installing Shrink Tubing

Courtesy of FORD MOTOR CO.