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 variant/trim than selected.

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 Proper Wire Strip
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 Appropriate Crimping Chamber On Rotunda 164-R5901 Pro-Crimper
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: Placing Brazed Seam Toward Indenter
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: Checking For Acceptable 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: Heating Repaired Area Until Adhesive Flows Out Of Both Ends Of Heat 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: 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.