When replacing or repairing a wire or connector, it is important that the correct gauge wire be used as shown in the service manual wiring diagrams or in the following wire substitution chart. The substitution chart shows the applicable gauge replacement wire size that can be used if necessary to substitute for the original gauge wire size.

Replacement Wire Size Original Wire Size
Use 12 gauge For 12, 14 and 16 gauge wires
Use 14 gauge For 14, 16 and 18 gauge wires
Use 16 gauge For 16, 18 and 20 gauge wires
Use 18 gauge For 18 and 20 gauge wires

1. Disconnect battery negative cable.

2. Remove 1/2 inch of insulation from each end of the wire.

3. Place a piece of adhesive lined heat shrink tubing over one side of the
    wire. Make sure the tubing will be long enough to cover and seal the entire
    repair area.

4. Place the strands of wire overlapping each other (figure 1) inside of the
    splice clip.


5. Using crimping tool 05019912AA, crimp the splice clip and wires together
    (figure 2).



6. Solder the connection together using rosin core type solder only
    (figure 3)
.     Do not use Acid Core solder.



7. Center the heat shrink tubing over the splice 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 (figure 4).



8. Secure the wire to the existing ones to prevent chafing or damage to the

9. Connect battery and test all affected systems.


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