Twisted Wire Harnesses

It is important to make sure that the number of turns over the repair length is counted at the start of the repair. Make sure that the same number of turns are reintroduced before fitting the terminals into the connector. If the original number of turns cannot be reintroduced on a twisted wire, the following dimensions must not be exceeded.

It is important to maintain the correct number of twists per meter. It is suggested that the number of twists are counted over a set length. For example, if there are 50 twists/m, count the number of twists over 10cm (3.94 inches) of a representative section of the cable. This is to confirm that the number of twists is enough.

For a cable that has 50 twists/m, each twist is taking 2 cm (0.79 inches). Therefore, in 10 cm there will be at least 5 complete twists to consider that the twisting is acceptable. It is also important to compare the rest of the cable to confirm it visually has the same twisting.

The length of an untwisted part of a harness includes both ends. The image below shows untwisted sections and an indication of 1 twist.

Courtesy of JAGUAR LAND ROVER NORTH AMERICA, LLC