Recommended Splicing Method - Solder (For 16 AWG/1.0mm And Smaller Diameter Wire Only)

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 wires to appropriate length.

Fig 1: Identifying Wires Stripping Dimensions
Courtesy of FORD MOTOR CO.
Install heat shrink tubing
Twist wires together.
Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.

NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 AWG/0.5-1.0mm) or ES-2 (10-18 AWG/0.8-5.0mm) to seal wire splice.

Fig 2: Inserting Stripped Wire Into Barrel
Courtesy of FORD MOTOR CO.
Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.

Fig 3: Identifying Heat Shrink Tubing Installation Dimensions On Wire
Courtesy of FORD MOTOR CO.
Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing.
NOTE: On smaller wires, use pliers to gently squeeze the ends of the heat shrink sleeve (while heat shrink is still warm) to ensure a tight fit and close any air gaps

Fig 4: Squeezing Ends Of Heat Shrink Sleeve (While Heat Shrink Still Warm)
Courtesy of FORD MOTOR CO.
Reconnect battery ground cable.