J-38125 Terminal Repair Kit
Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection.
Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.
Splice Sleeve Color | Crimp Tool Nest Color | Wire Gage mm² / (AWG) |
---|---|---|
Salmon (Yellow-Pink) 12089189 | Red (1) | 0.035-0.8/(18-20) |
Blue 12089190 | Blue (2) | 1-2/(14-16) |
Yellow 12089191 | Yellow (3) | 3-5/(10-12) |
Green 88988379 | Red (1) | 0.22-0.35/(22-26) |
Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.
• | Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. |
• | Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. |
• | Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. |
Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.
• | When adding a length of wire to the existing harness, use the same size wire as the original wire. |
• | Perform one of the following items in order to find the correct wire size: |
- | Find the wire on the schematic and convert the metric size to the equivalent AWG size. |
- | Use an AWG wire gage. |
- | If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. |
• | Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. |
• | Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. |
• | If the wire is damaged, repeat this procedure after removing the damaged section. |
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
• | The tubing will shrink completely as the heat is moved along the insulation. |
• | A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. |