MAINTENANCE OF HARNESS
Minor repairs of the harness assembly, such as replacement of contact springs, sleeves, compression
springs, eyelets, or grommets is accomplished with the harness mounted on the engine. Lead assemblies are
also replaced with harness mounted on the engine unless inaccessibility of installation or number of leads to be
replaced makes it unreasonable.
To remove and replace grommets or eyelets proceed as follows:
1. Pull conductor through shielding sufficiently to make eyelet accessible.
2. Remove eyelet, being careful not to damage conductor wire.
3. Replace grommet and eyelet with AB groove of Crimping Tool No. 114152 or a pair of diagonal pliers
modified as shown in figure 74-22.
4. Work wire back into shielding so grommet fits properly against ferrules in plate.
5. Remove slack in shielding or wire by grasping lead in one hand and sliding other hand firmly along
lead towards magneto cover.
To replace contact springs, insulating sleeves, compression spring, or elbows, proceed as follows:
1. Use a Bendix l l-7073 needle or a mechanical pencil with the lead retracted to hook end of contact
spring as shown in figure 74-23.
2. Use needle or pencil to unscrew spring.
3. Slide insulating sleeve and spring retainer assembly off end of lead assembly.
4. Replace defective component and reassemble as follows:
a. Fabricate a tool as shown in figure 74-24 for installing insulating sleeves over cable terminals.
b. Slide elbow assembly over lead and attach nut finger tight to ferrule.
c. Push fabricated tool through insulating sleeve and spring retainer assembly as shown in figure
74-25. Screw cable terminal into tool.
d. Work insulating sleeve and spring retainer assembly into position over cable and unscrew tool.
Install contact spring on cable terminal.
—NOTE—
It may be necessary to lubricate the cable and insulating sleeve
with a thin film of DC-200 (200,000 centistokes) or commercial
grade alcohol to facilitate assembly.
5. To replace one of the lead assemblies, proceed as follows:
a. Remove clamps and brackets from defective lead assembly. Cut cable ties from assembly and
discard.
b. Cut eyelet from lead and remove grommet.
c. Grip ferrule of lead with a vise grip or water pump pliers. With a twist-pull action, remove ferrule
from cover and discard ferrule. Pull lead from cover.
d. Thread pre-stripped end of replacement lead through cover.
—NOTE—
Replacement leads are available from Bendix in lengths of 17
thru 74 inches in 3 inch increments. Use nearest next longer
length to replace defective lead.
74 - 21 - 00
Page - 74-20
Reissued: August 1, 1986
2J16
PIPER AIRCRAFT
PA-28-236
MAINTENANCE MANUAL
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