TM 5-3895-373-20
B.
REPAIR - Continued.
f.
Slide shrink tubing (40) over terminal (38) at
wire connection.
g.
Secure shrink tubing (40) onto terminal (38)
with a heat gun.
5.
REPAIR ELECTRICAL WIRING HARNESSES
BY RUNNING A REPLACEMENT WIRE
"PIGGYBACK" ALONG EXISTING WIRING
HARNESS.
NOTE
The following is an example of how
to
replace
a
damaged
wire
by
piggybacking
a
replacement
wire
along side electrical wiring harness
to be repaired. Treat each end as a
separate repair. You may replace a
connector on one end and splice on
the opposite end.
a.
After determining a wire is damaged inside
a wiring harness, repair using one of the
following methods:
b.
Cut defective wire (41) about 3.0 in. (76,2
mm) from connector (42) on both ends of
wiring harness and continue with steps d
through i.
c.
Remove pin terminals from connectors at
each end of affected wire and replace with
new wire and pin terminals. Refer to B.2
and proceed to step d.
d.
Using a replacement wire of same gauge,
install wire along harness cover (43) on
wiring harness, fastening wire to harness
cover with tie wraps (44) at 3.0 in.(76,2 mm)
intervals.
NOTE
Allow at least 1.0 in. (25,4 mm) of
slack in replacement wire for splicing.
e.
Use wire strippers to strip approximately
0.25 in. (6,3 mm) from ends of defective
wire (41).
f.
Install shrink tubing over defective wire (41)
and slide away from ends of wire to allow
splicing.
g.
Splice and solder wires together per MIL-
STD-2000A with soldering iron and splice
clips.
h.
Cover soldered joint with shrink tubing and
secure with heat gun.
i.
Repair any rips or tears in wiring harness
cover (43) with electrical tape.
6.
REPLACE ANY TIE WRAPS THAT HAVE
BEEN) REMOVED FROM
WIRING
HARNESS DURING REPAIR PROCESS AS
NEEDED.
GO TO NEXT PAGE
’7-167
