Recommended splicing method — solder — 2016 workshop reference 6235

Transcribed from scanned source material. Text and illustration placement checked against the supplied source.

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.

1. Disconnect battery ground cable.

2. Strip wires to appropriate length.

Solder splice wire preparation: 19.5 mm (¾ in) on each wire · source reference 6235Original colors & callouts · Select to enlarge

3. Install heat shrink tubing.

4. Twist wires together.

5. 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.

Soldered wire splice and shrink tubing placement, 12.7 mm (½ in) · source reference 6235Original colors & callouts · Select to enlarge

6. Evenly position heat shrink tubing over wire repair.

NOTE: Overlap tubing on both wires.

Heat shrink tubing overlap dimensions · source reference 6235Original colors & callouts · Select to enlarge

7. 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

8. Reconnect battery ground cable.

Source reference 6235

2016 Mustang workshop publication supplied to Mustang Atlas. Original technical text and illustrations; HTML formatting by Mustang Atlas. Source page numbering is retained for traceability. Follow the configuration, revision, warnings, and cross-references in the material. About this edition.