Repair wiring harness by means of axial solder connectors - AR54.18-P-0100-06A

Expose damaged cable or plug/coupling in easily accessible position and cut off.
Separate cores in wiring harness offset by approx. 45 mm.

Fig 1: Identifying Wiring Harness Offset
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Cut new section of cable to match old cable.
Remove 15 mm of insulation at end of cables.
Pull cut-off insulation off the line while turning.

Fig 2: Identifying Cable Insulation Dimensions
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Select axial solder connector by means of cable cross-section.
Push the axial solder connector on line beyond the solder point.
Push on the thinner side of the axial solder connector first.

Fig 3: Pushing On Axial Solder Connector
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Twist the line ends together.
Push back the axial solder connector on the transposition while turning.

Fig 4: Twisting Line Ends
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Heat up axial solder connector with a preheated hot air blower (with electronic temperature control) to 400°C.
Hot air blower

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Use welding bead catcher in the vehicle interior in order to avoid damage due to liquid solder.

Until the soldering ring has dissolved and the covering has positioned itself properly around the lines.

Fig 5: Heating Axial Solder Connector
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Check soldered point.
It must not be possible to see the soldering ring of the axial soldered connector any more. The covering must contact the lines properly.

Fig 6: Identifying Correct And Incorrect Position Of Soldered Point
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Apply axial solder connector to the lines and wrap repaired area round with fabric tape.
The axial solder connectors must not lie directly above one another.

Fig 7: Wrapping Repaired Area
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