2-20 Electrical
Section 2: Electrical
Splices and Repairs
WARNING: Do NOT splice into or repair high-voltage (orange) wiring/cables. The high
voltage in this system is 275 volts DC. Failure to follow these instructions may result in
severe personal injury or death.
• Stagger the splices within a harness to reduce increased harness diameter. Splice only on
straight areas as installed, not on bends.
• Strip wire ends, making sure that individual conductor strands are not damaged.
• When soldering, make sure an adequate mechanical joint exists before applying solder. Use only
resin-core solder. Acid-core solder should not be used since it may result in corrosion.
• For crimp joints, use butt-type metal barrel fasteners and the proper tool at the appropriate
setting for the wire size (such as Motorcraft Crimp Tool S-9796) specifically designed for this
type of work.
• Make sure splice joints are adequately sealed and insulated. In an outside environment, use
Duraseal butt connectors or equivalent. A durable substitute splice joint can be achieved by
using a bare metal barrel, crimping, flow-soldering and covering with shrink tubing. Quality
electrical tape can be used inside the vehicle but is not recommended for an outside
environment.
• Be sure that the new wire is not a lesser gauge than its original mating wire.
Recommended Splicing Method — Solder (For 16 AWG and Smaller Diameter Wire
Only)
1. Disconnect the battery ground cable.
2012 Fusion Hybrid, MKZ Hybrid Modifiers Guide, 09/2011
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