Splicing Twisted or Shielded Cable

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WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose® speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable.

Fig 1: View Of Outer Wiring Jacket

Courtesy of GENERAL MOTORS CORP.

Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape.
Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made.

Fig 2: Preparing The Splice

Courtesy of GENERAL MOTORS CORP.

Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended.

IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire.

Fig 3: Identifying Diode On Wire

Courtesy of GENERAL MOTORS CORP.

Re-assemble the cable.
- Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape.
- Use caution not to wrap the drain wire in the tape (1).
- Follow the splicing instructions for copper wire and splice the drain wire.
- Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation.

Fig 4: View Of Repaired Wire Covered With Electrical Tape

Courtesy of GENERAL MOTORS CORP.

Tape over the entire cable. Use a winding motion when you apply the tape.