(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 13).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push down on the yellow connector locking tab
to release the terminals (Fig. 14).
(4) Using special tool 6932, push the terminal to
remove it from the connector (Fig. 15).
(5) Repair or replace the connector or terminal as
necessary.
(6) When re-assembling the connector, the locking
wedge must be placed in the locked position to pre-
vent terminal push out.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 16).
(3) Remove connector locking wedge, if required
(Fig. 16).
Fig. 11 Terminal Removal
1 – CONNECTOR
2 – FROM SPECIAL TOOL KIT 6680
Fig. 12 Terminal Removal Using Special Tool
1 – FROM SPECIAL TOOL KIT 6680
2 – CONNECTOR
Fig. 13 Stagger Cutting Wires
1 – REPAIR SIDE WIRES
2 – STAGER CUTS
3 – HARNESS WIRES
8W - 01 - 12 8W - 01 GENERAL INFORMATION LH
SERVICE PROCEDURES (Continued)
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