Weatherpack™ Wiring Repair

WARNING: This page is about a different car, the 2019 GMC Savana 3500, 2019 GMC Savana 2500, 2019 Chevrolet Express 3500, and 2019 Chevrolet Express 2500. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Some replacement pigtail connectors may be delivered without the terminated leads installed into the connector. For Weatherpack™ connectors, all terminated leads included in the package should to be installed into the connector. If the connector end view shows that a terminal is not occupied, the extra terminated lead(s) need to be installed and the end(s) sealed using a DuraSeal splice sleeve and taped back into the harness.

Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires 0.35 and 0.13 mm² (22 to 26 gauge) wires and for splicing wires of different gauges.

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Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Holding the DuraSEAL with one hand gently tug on the wire to ensure it is crimped in the DuraSeal.
Using the EL-38125-5A Ultra Torch Special Tool, apply heat to the crimped area of the barrel.
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Start in the middle and gradually move the heat barrel to the open ends of the tubing:
- The tubing will shrink completely as the heat is moved along the insulation.
- A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.
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Tape the excess terminated lead(s) back into the harness. The tape should cover the harness by 25 mm (1 Inch). Use care to make sure the taping does not cause strain on the wiring and terminals, Improper taping can cause wire and terminal fretting.