TM 5-3895-373-20B.REPAIR - Continued.f.Slide shrink tubing (40) over terminal (38) atwire connection.g.Secure shrink tubing (40) onto terminal (38)with a heat gun.5.REPAIR ELECTRICAL WIRING HARNESSESBY RUNNING A REPLACEMENT WIRE"PIGGYBACK" ALONG EXISTING WIRINGHARNESS.NOTEThe following is an example of howto replace a damaged wire bypiggybacking a replacement wirealong side electrical wiring harnessto be repaired. Treat each end as aseparate repair. You may replace aconnector on one end and splice onthe opposite end.a.After determining a wire is damaged insidea wiring harness, repair using one of thefollowing methods:b.Cut defective wire (41) about 3.0 in. (76,2mm) from connector (42) on both ends ofwiring harness and continue with steps dthrough i.c.Remove pin terminals from connectors ateach end of affected wire and replace withnew wire and pin terminals. Refer to B.2and proceed to step d.d.Using a replacement wire of same gauge,install wire along harness cover (43) onwiring harness, fastening wire to harnesscover with tie wraps (44) at 3.0 in.(76,2 mm)intervals.NOTEAllow at least 1.0 in. (25,4 mm) ofslack in replacement wire for splicing.e.Use wire strippers to strip approximately0.25 in. (6,3 mm) from ends of defectivewire (41).f.Install shrink tubing over defective wire (41)and slide away from ends of wire to allowsplicing.g.Splice and solder wires together per MIL-STD-2000A with soldering iron and spliceclips.h.Cover soldered joint with shrink tubing andsecure with heat gun.i.Repair any rips or tears in wiring harnesscover (43) with electrical tape.6.REPLACE ANY TIE WRAPS THAT HAVEBEEN) REMOVED FROMWIRINGHARNESS DURING REPAIR PROCESS ASNEEDED.GO TO NEXT PAGE’7-167
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