1. WIRE REPAIR
Chapter 4

2. TROUBLESHOOTING STEPS
Confirm the Complaint
Study the electrical schematic
Locate and repair the fault
Test the repair

3. WIRE REPAIR Pg L84 Type of Repair required Ease of Access
Type of conductor
Size of wire
Circuit requirements
Manufacturer's recommendations

4. WIRE SIZE Less resistance in stranded wire Larger gauge number means
Page C85-87
Less resistance in
stranded wire
Larger gauge
number means
smaller wire
Copper wire is
flexible and
inexpensive

5. AWG to METRIC Wire Sizes
Page C87

6. WIRE MARKINGS

7. HEAT SINK
When soldering
electronics use heat
sink

8. Page L91
SOLDER JOINT

9. “W”
CRIMP
Page L87

10. Page L90
SOLDER LUG

11. FUSIBLE LINK REPAIR Page L93 1. Remove damaged fusible link
2. Prepare cut wire end for
new fusible link
3. Install crimp style lug
4. Install new fusible link by
crimping link to lug
5. Solder link to lug also
6. Apply Heat Shrink to
connection

12. HEAT SHRINK Cut Wire Insulation and Strip off Install Crimp terminal
Prepare Heat Shrink
Install Heat Shrink
Apply heat to Heat Shrink tube

13. SHEILDED CABLE REPAIR Page L93 Cut out damaged section of wire
Remove 1 inch out outer insulation
Unwrap Mylar tape
Splice Cut wires
Wrap Mylar tape
Splice Drain Wire

14. SOLDERING OF TERMINAL Strip Wire as normal
Form wire terminal around insulation
Form wire strands on terminal
Solder Strands to terminal

15. TERMINAL TYPES Page L85 Crimp Style Non-crimp Style
Different wire gauge sizes.
Color codes
Quality

16. CONNECTORS Page C88 & L98 TYPES ALL USE SOME TYPE OF TERMINAL LOCK
MOLDED
MUTIPLE WIRE
BULKHEAD
WEATHER-PACK
METRI-PACK
ALL USE SOME TYPE OF TERMINAL LOCK
Page C88 & L98

17. TERMINAL TOOLS Page C89 & L97 Bullet Style Spade Style
Must use to unlock terminal locks
Use push-to-seat and pull-to-seat

18. PRINTED CIRCUIT BOARDS
Page C91
Used on Instrument Panels
Made of thin phenolic or fiberglass board
Conductive metal is etched to make circuits.
Must use care when servicing printed circuit board. Tears, oil off fingers, etc.

19. TYPICAL PRINTED CIRCUIT BOARD

20. That’s All folks!