Splicing Copper Wire Using Splice Clips

If only wire insulation is damaged, find and correct cause of damage:
- If damage is minor, tape over wire.
- If damage is more extensive, replace faulty wire as follows:

1. Open harness
- If harness is taped, remove tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open harness (available from sewing supply stores).
- If harness has a black plastic conduit, pull out desired wires.

2. Cut wire
- Cut off as little wire as possible. Extra length may be needed to change location of a splice to assure that each splice is at least 40mm (1.5 in.) away from other splices, harness branches, or connectors.

Splicing Copper Wire Using Splice Clips:

3. Strip Insulation
- When replacing a wire, use a wire of equal or larger size than the original. Schematics show wire sizes in metric units. Use the following table to convert metric units to commercial (AWG) wire sizes (each AWG size is equal to or larger than the equivalent metric size).
- If a wire Size is not known, start with the largest opening of a wire stripper and work down until a clean strip of insulation is removed.
- If Wire is nicked or Cut, repeat procedure on a new section of Wire. The two wire ends to be spliced should be of equal length.

Splicing Copper Wire Using Splice Clips:

4. Crimp wires
- Select the proper size clip to secure the splice. To determine proper clip size, follow instructions Included with clips.
- Select the proper anvil on the crimper.
- Overlap the two stripped wire ends and hold them between thumb and forefinger. Center splice clip under stripped wires and hold in place.

Splicing Copper Wire Using Splice Clips:

- Open crimping tool to its full width and rest one handle on a firm flat surface.
- Center back of splice clip on anvil and close crimping tool to the point where the former touches the wings of the clip.
- Assure clip and wires are still in the correct position, then apply pressure until crimping tool closes.
- Before crimping ends of clip, assure that:
1. Wires extend beyond clip in each direction.
2. No Strands of wire are cut loose.
3. No Insulation is caught under clip.

Splicing Copper Wire Using Splice Clips:

- Crimp splice again, once on each end. Do not let crimping tool extend beyond the edge of clip as wires may be damaged.

Splicing Copper Wire Using Splice Clips:

5. Solder
- Apply 60/40 rosin core solder to the opening in back of clip. Follow manufacturer's Instructions for the soldering equipment being used.

Splicing Copper Wire Using Splice Clips (Good (Rolled), Bad (Flagged)):

6. Tape splice
- Center and roll splicing tape. Tape should cover entire splice. Roll on enough tape to duplicate insulation thickness of existing wires. Do not flag tape as it may not provide enough insulation and flagged ends may tangle with other wires in harness.
- If wire does not belong in a conduit or harness covering, tape wire again. Use a winding motion to cover first piece of tape.