Repairing wiring harness using soldered terminal sleeve - AR54.18-P-0100-02A

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1004-20A	Hot-air gun

Expose damaged cable or connector/socket at an easily accessible point and cut off.
Separate conductors in wiring harness offset by approx. 45 mm.

Fig 1: Identifying Conductors In Wiring Harness Offset
Cut new cable to size matching the old part.
When cutting to size, allow an additional length of 50 mm for creating loops (cable grip).
Remove insulation at ends of cable over 15 mm.
Select soldered terminal sleeve according to the table below.

Fig 2: Identifying Insulation Ends Of Cable Over
Insert cables into matching soldered terminal sleeve (Z), matching the total cross-section of the cable.
Turn soldered terminal sleeve (7) fully onto the cables.

Fig 3: Inserting Cables Into Matching Soldered Terminal Sleeve
Heat soldered terminal sleeve with a hot air gun (approx. 400 °C).
Begin at the tapered side until the soldered ring detaches and the sheathing has moved cleanly around the cable.

Fig 4: Heating Soldered Terminal Sleeve
Inspect solder point.
It must no longer be possible to see the soldered ring (1) on the soldered connector sleeve (Z). The sheathing (2) must be resting cleanly against the cables.

Fig 5: Identifying Correct Incorrect Sleeve Position
Position soldered connector sleeves at cable and wrap fabric tape around repaired area.
Soldered connector sleeves must not be positioned directly one above the other.

Fig 6: Identifying Connector Sleeves Repaired Area