Quick Reference For Using Solder Sleeve Connectors
Quick Reference for Using Solder Sleeve Connectors
A. Strip about 10 mm of insulation from the ends of the wires.
NOTE:
^ Use the correct size opening in the Wire Crimper tool so you won't cut off any strands of wire.
^ Less strands reduce the ability of the wire to handle the expected electrical load.
B. Slide a Solder Sleeve Connector over the wire.
C. Make sure the wires are securely twisted together.
D. Position the Solder Sleeve Connector so that the solder ring (in the connector) is centered around the exposed twisted wire area (see Figure D).
E. Use the special Flameless Heat Gun-J-46538 to heat the Solder Connector.
This operation will:
^ Melt the solder (silver ring inside the Solder Sleeve Connector) into the exposed twisted wire area.
^ Melt the sealant (red rings inside solder connector) onto the wires.
^ Shrink the plastic sleeve onto the wires.
Important Soldering Tips:
^ Position the solder connector in the middle of the heat shield of the heat gun.
^ Start heating the connector from the center and move back and forth (side to side) and around to allow even distribution of the heat to the entire connector.
^ Make sure the solder completely flows into the exposed twisted wires and the adhesive properly seals the wire insulation to the connector sleeve. Stop applying the heat immediately after this happens.
WARNING:
^ The Flame-Less Heat Gun and the Solder Sleeve Connectors become HOT during the soldering process.
^ Allow the gun and connectors to cool down before handling them.
CAUTION:
Be careful not to damage the connector or wires with the heat gun:
^ Do NOT apply heat for more than about 40 seconds.
^ Do NOT overheat the connector or wires (i.e. severe darkening of connector sleeve or wire insulation).
10. Wrap the harness with electrical tape as shown.
^ The harness will have two branches.
11. Push in the new sub-connector until it locks in place.
NOTE:
It will lock in place in only one direction.
12. Slide the male connector back onto its mount.
13. Reattach the harness mount.
14. Cover the male side of the connector with tape.
^ This tape will prevent debris entering connector during the remainder of the repair.
Female Sub-Connector
15. Remove the harness covering 3 to 4 inches back from the connector.
16. Remove the female sub-connector as follows:
a. Insert the release tools (J-50778) as show in Figure 35.
^ Make sure the wedge of the tools are facing away from the sub-connector (facing outboard) as shown in Figure 35.
b. Hold the release tools in place and pull out the sub-connector.
17. Cut the female sub-connector from the harness.
a. Cut the harness close to the connector.
18. Get the new female sub-connector from the repair kit.
NOTE:
The wires on the sub-connector are cut to three different lengths.
19. Attach the new female sub-connector to the harness as follows (see Figure 39):
a. Start with one of the shortest wires on the sub-connector.
b. Match the wire color exactly to the harness wire.
c. Use a solder sleeve connector to attach the wires.
^ Refer to ITB03-054 for complete details on using the Flameless Heat Gun and Solder Sleeve Connectors.
^ Refer to "Quick Reference Foe Using Solder Sleeve Connectors" in this bulletin as a quick reference for using these tools.
d. Repeat a, b and c above for all the wires.
^ Attach them in the order of shortest to longest from the sub-connector.
^ Cut the wire length on the harness side as needed.
^ Make sure all of the wire colors match exactly.
20. Push in the new sub-connector until it locks in place.
NOTE:
It will lock in place in only one direction.
21. Fold (loop) the repaired wires as shown.
22. Wrap the harness with electrical tape as shown.
23. Install the protective cover (cover) over the female connector as shown in Figure 43.
24. Slide the cover on the harness toward the connector as far as possible until the cover is touching the top of the connector.
25. Position the cover so the slit is facing the engine when the connector is reconnected.
26. Tape the cover to the harness as shown.
^ Squeeze the cover so the edges of the slit are touching.
27. Tape over the cover and the harness as shown.
^ Start at the cover and work toward the harness.
^ Overlap the tape layers. Do not leave any gaps.
28. Remove tape from the opening of the male connector end.
29. Reconnect the connector as follows:
a. Make sure the connector latch is in the UP (disconnected) position.
b. Push the female end into the male end.
^ As you push in the female end the latch will move to the 1/2 position.
c. Move the latch to the DOWN position and snap it (lock it) in place.
30. Make sure the cover is over the connector as shown.
31. Reinstall the battery and the battery hold-down.
32. Connect the battery cables - positive cable first.
33. Remove tape from the lower edge of the windshield.
34. Reinstall the cowl top cover RH.
35. Reinstall the hoodledge cover RH.
36. Reinstall the battery cover.
37. Reset the clock and the radio station presets.
38. Reset / Re-initialize power windows power sunroof AIC etc. as needed.
^ For details refer to Additional Service When Removing Battery Negative Terminal in the GI section of the appropriate Service Manual.
39. Inform the customer they will need to reset the memory of their Auto Drive Position.