01/08/2023 16:49:04

Double Splice Repair Procedure

Repairing an electrical harness using two splices.

Procedure

  1. Disconnect all of the necessary electrical connectors to electrically isolate the harness from the vehicle, or disconnect low voltage (LV) power.
  2. Use a multimeter to check for voltage on the circuit being repaired.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not perform this procedure while the circuit is energized.
  3. Make sure that there is enough room to work comfortably on the circuit being repaired.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Protect all surfaces that can be damaged by heat in later steps.
  4. Note the original routing of the wire.
  5. Photograph the damaged area.
  6. Refer to the circuit diagram to find the correct wire size.
  7. Refer to the Electrical Harness Repair Guidelines section of this document to find the proper crimp barrel and heat shrink tube for the size of the wire.
  8. Cut the wire to remove the damaged portion.
    Informational PurposesAn informational icon, calling your attention
    Note
    Minimize the amount of wire removed.
  9. Cut a section of new wire that is at least 100 mm longer than the damaged portion.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that there is at least 100 mm of new wire to enable adequate slack when the second end of the wire is spliced.
  10. Slide the heat shrink tube over one end of the wire.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not skip this step. The procedure will have to be repeated if the wire is joined before installing the heat shrink tube.
  11. Complete the first splice, using the applicable steps in the Single Splice Repair Procedure section of this document.
  12. Cut the repair section to length.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Leave enough length to properly insert the stripped ends into the crimp barrel. Wires that are too short put excess strain on the wire where it enters the connector or harness transition.
  13. Slide the heat shrink tube over one end of the wire.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not skip this step. The procedure will have to be repeated if the wire is joined without installing the heat shrink tube.
  14. Complete the second splice, using the applicable steps in the Single Splice Repair Procedure section of this document.