Wiring - Repair Instruction Sheets
91chrysler04
NO.: 08-07-91
GROUP: ELECTRICAL
DATE: May 20, 1991
SUBJECT: Wiring Repair Instruction Sheets
MODELS:
ALL CHRYSLER/PLYMOUTH/DODGE VEHICLES
DISCUSSION:
Wiring repairs can now be made using service repair packages available through the parts system. These packages allow for repair or replacement of individual wiring harness components rather than replacement of a complete wiring harness.
Some of these packages were released without instruction sheets. When making a wiring repair using a service repair package that does not contain an instruction sheet, use one of the three attached instruction sheets.
REPAIR INSTRUCTION PAGE PART NUMBER
SHEET FOR:
Wiring Connector/
Terminal Assembly 2 K6853037
Wiring Connector 3 K6853038
(Damaged Connector Repairs)
Wiring Terminal 4 K6853039
(Damaged Terminal Repairs)
INSTRUCTION SHEET FOR WIRING CONNECTORS AND TERMINALS
1. With the ignition key in the OFF position, disconnect the battery.
2. Disconnect the wiring connector from its mating half.
3. Cut off the existing wiring connector directly behind the insulator and remove about six inches of tape if there is any present.
4. Stagger cut all wires on the vehicle harness side about 1/2" apart.
5. Strip the insulation off the end of each wire on the vehicle wire harness about one inch.
6. Stagger cut the matching wires on the repair wire assembly in the opposite order as you did on the vehicle wire harness side (allowing extra length for soldered connections). Be sure that the overall length of the new repaired wiring is the same as the original. Strip the insulation of the end of each wire on the repair harness about one inch.
7. Slide a piece of the heat shrink tubing onto each wire of the repair harness.
8. Connect wire harness end to the repair wire end by twisting ends together. Be sure to match wire colors.
9. Solder twisted wire ends using rosin core solder.
10. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat tubing to shrink and seal splice. Use an approved air heat gun only.
11. Re-tape wire harness over splice up to 1-1/2" behind the back of the connector.
12. Connect the wiring connector to its mating half.
13. Reconnect battery.
14. Test system.
INSTRUCTION SHEET FOR SERVICING A WIRING CONNECTOR
1. With the ignition key in the OFF position, disconnect the battery.
2. Disconnect the connector that is to be repaired from its mating half.
3. Carefully remove the wiring connector locking wedge from the connector so the connector locking finger can be accessed.
4. Position the connector locking finger away from the terminal while pulling on the wire to remove the terminal from the connector.
5. Reset the terminal locking tang if it has one.
6. Insert the removed wire in the same cavity on the repair connector.
7. Repeat steps 3-6 for each cavity on the connector being sure that all wires are inserted into the proper cavities.
8. Insert the connector locking wedge into the repair connector.
9. Connect the repaired connector to its mating half.
10. Reconnect battery.
11. Test system.
INSTRUCTION SHEET FOR WIRING TERMINALS
1. With the ignition key in the OFF position, disconnect the battery.
2. Disconnect the wiring connector from its mating half.
3. Carefully remove the wiring connector locking wedge from the connector so the connector locking finger can be accessed.
4. Position the connector locking finger away from the terminal while pulling on the wire to remove the terminal from the connector.
5. Cut the wire about six inches from the back of the connector.
6. Strip the insulation off the end of the wire on the vehicle wire harness about one inch.
7. Find the wire from the terminal repair wire assembly that best matches the color of wire you are repairing. Cut the repair wire to the proper length. Strip the insulation off the end of the repair wire about one inch.
8. Slide a piece of the heat shrink tubing onto the repair wire.
9. Connect wire harness end to the repair wire end by twisting ends together. Be sure to match wire colors as closely as possible.
10. Solder twisted wire ends using rosin core solder.
11. Slide down the piece of heat shrink tubing to cover the splice. Be careful to center splice inside tubing. Heat tubing to shrink and seal splice. Use an approved air heat gun only.
12. Insert the terminal from the wire repair side into the proper cavity in the connector.
13. Insert the connector locking wedge into the connector.
14. Re-tape wire harness over splices up to 1-1/2" behind the back of the connector.
15. Connect the wiring connector to its mating half.
16. Reconnect battery.
17. Test system.