Adjuster Assembly Wiring Repair

If any adjuster assembly wiring is damaged, Terminal Repair Kit (J38125-A) is used to repair sensitive, low energy circuits with special Sealed Splices. Terminal Repair Kit (J38125-A) also contains a special Splice Crimping Tool (J38125-8), heat torch and instruction manual for these splices. The following steps are used to repair damaged wires:

1. If harness is taped, use a sewing ripper (available from sewing supply stores) to remove tape and avoid damaging wire insulation. Crimp and sealed splice sleeves may be used on all types of insulation except tefzel and coaxial, and may only be used to form a one-to-one splice.
2. Cut as little wire from harness as possible. If more than one splice is necessary, ensure that splices will be at least 1.5" (38 mm) away from other splices, harness branches or connectors.
NOTE: It is important that the following procedures be performed in order. If any wire strand is damaged, repeat procedure until a clean strip with all wire strands intact is obtained.
3. Using an AWG wire gauge, determine wire size. Using a wire stripper, remove approximately 5/16" (7.9 mm) of insulation from wire to be spliced. Avoid nicking or cutting any strands of wire. If wire is dam-aged, repeat this procedure after removing damaged section.
4. Select proper sealed splice sleeve according to wire size. Splice sleeves and Splice Crimp Tool (J38125-8) nests are color and size coded. See CRIMP & SEAL SPLICE COLOR CHART table. Using crimp tool, position splice sleeve in proper nest and grip midway between end of barrel and wire stop. There is a stop in the middle of barrel to keep wire from going too far into sleeve.
5. Insert wire into splice sleeve until it hits barrel stop. Close handles of crimp tool tightly until crimper handles open when released. Crimper handles will not open until proper amount of pressure is applied to splice sleeve. Repeat previous steps for opposite end of splice.
6. Using heat torch, apply heat where barrel is crimped. Gradually move heat to open end of tubing, shrinking tubing completely as heat is moved along insulation. A small amount of sealant will come out of end of tubing when sufficient shrinking is achieved.