SIR Wire Repair

Tool Required

J 38125-A Terminal Repair Kit

If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5, 0.8, 1.0, etc.). Use the sealed splices and splice crimping tool from J 38125-A Terminal Repair Kit for these repairs. Use the following wiring repair procedures to ensure the integrity of the sealed splice.
1. Open the harness by removing the tape.
- To avoid wire insulation damage use a sewing seam ripper (available from sewing supply stores) to cut open the harness.
- Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial.
- Do not use the crimp and sealed splice sleeve to form a splice with greater than two wires coming together.

2. Cut the wire.
- Cut as little wire off the harness as possible. You may need the extra length of wire to change the location of a splice.
- Adjust splice locations so that each splice is at least 40 mm (1.5 inches) away from other splices, harness branches, or connectors.

NOTICE: Follow these procedures in the order listed. If the wire strands are damaged, repeat the procedure until a clean strip with all wire strands intact is obtained.

3. Strip the insulation.
- When adding a length of wire to the existing harness, be certain to use the same size wire as the original wire.
- To find the correct wire size do one of the following:
- 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.

4. Strip approximately 7.5 mm (0.313 inch) of insulation from each wire to be spliced.
- Be careful to avoid nicking or cutting any of the strands. Check the stripped wire for nicks or cut strands.
- If the wire is damaged, repeat step four after removing the damaged section.

5. Select the splice sleeve.
- Select the proper sealed splice sleeve according to wire size.
- The splice sleeves and tool nests are color coded.