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TM 5-2420-222-34
1-22.
WIRE REPLACEMENT (Con’t).
d.
Cut new wire of same gage and type as wire being replaced to desired length using diagonal-cutting pliers.
NOTE
Always use heat shrink tubing around wire splices or wrap them with electrical
tape.
e.
Slide new length of heat shrink tubing (Item 41, Appendix B) onto ends of new wire If desired. If tubing is not
available, use electrical tape (Item 36, Appendix B).
f.
Connect terminal lugs or connectors to wire by soldering or crimping as required. Ensure that connections
are tight.
g.
To splice wires together, twist and tie end strands of each wire separately. After tinned ends have cooled,
twist both ends together and reheat with soldering gun to fuse ends together.
h.
If heat shrink tubing (Item 41, Appendix B) is used, slide tubing over connections and shrink in place (see
paragraph 1-20).
1-23.
WIRING HARNESS CONNECTOR REPAIR AND REPLACEMENT.
All wiring harness connectors are of similar design and are repaired and replaced the same way. To repair or
replace Individual wires and pins, mating connectors must be disconnected, but it may not be necessary to remove
connectors from their mounting points. Repair or replace wiring harness connectors as follows:
WARNING
Although battery disconnect switch must be on and battery ground cable
connected to test electrical circuit voltage, turn off battery disconnect switch or
disconnect battery ground cable before doing resistance tests or replacing parts.
This will prevent electrical shock and damage to parts and equipment.
(1)
Unscrew retaining nut from connector and push back out of the way on wiring harness.
(2)
Pull retainer out of connector and slide back on wires to expose back of pins.
(3)
If replacing more than one wire or pin, tag each wire before removal with letter shown on face of
connector.
(4)
f replacing entire connector:
(a)
Using soldering gun, unsolder each wire from pin.
(b)
Discard defective connector.
(5)
If replacing individual wire or pin:
(a)
Using long roundnose pliers, pull pin out of connector.
(b)
Using soldering gun and long roundnose pliers, unsolder wire from pin.
(6)
Pull wire(s) out of holes in retainer and retaining nut.
(7)
Replace defective parts as required.
1-11
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