Recommended splicing method - Crimp (For 10-22 AWG(0.35-5.0mm) Diameter Wire to Like Wire Diameter)

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Cut and splice one circuit at a time noting the original wire to connector pin locations. This will avoid miss-connections.

Disconnect battery ground cable.
Strip 6.35mm (1/4 in) of insulation from each wire end, taking care not to nick or cut wire strands.
Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-26 AWG/0.13-1.0mm) or ES-2 (10-18 AWG/0.75-5.0mm) to seal wire splice.

Fig 1: Identifying Connector Components (Use Heat Shrinkable Tubes Marked With ES-1 (16-26 AWG/0.13-1.0mm)
Courtesy of FORD MOTOR CO.
Select appropriate wire splice for the wires to be spliced.
Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.

Fig 2: Identifying Connector Components (Cavity, Indenter)
Courtesy of FORD MOTOR CO.
Center one end of the wire splice in the appropriate crimping chamber.
If visible, be sure to place the brazed seam toward the indenter.
Insert stripped wire into the barrel.
Holding the wire in place, barrel squeeze tool handles appropriate ratchet releases.
Repeating steps 5-7, crimp the other half of the splice.
NOTE: It is recommended to apply solder at the ends of the barrel.

Fig 3: Identifying Connector Components (Indenter, Brazed Seam)
Courtesy of FORD MOTOR CO.
Check for acceptable crimp.
1. Crimp should be centered on each end of the butt splice.
2. Wire insulation does not enter butt splice.
3. Wire is visible through inspection hole of splices.

Fig 4: Identifying Connector Components (Crimp)

Courtesy of FORD MOTOR CO.

Evenly position supplied heat shrink tubing over wire repair.
Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing.
Reconnect battery ground cable.

Fig 5: Identifying Connector Components (Shrink Tubing)
Courtesy of FORD MOTOR CO.

This chart is to be used when pigtails or terminals are of different wire gauge than the vehicle harness.

Fig 6: Identifying Wire Size Chart

Courtesy of FORD MOTOR CO.

NOTE: If joining a smaller diameter vehicle wire size to a larger diameter pigtail, it is acceptable to cut strands from the pigtail to fit a barrel splice if necessary.