Hombre XS Space Cab 2WD V6-4.3L (1998)
Close secondary locks and join connector halves.
Repairing Connectors
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The following general repair procedures can be used to repair most types of connectors. The repair procedures are divided into three general
groups: Push to Seat, Pull to Seat and Weather Pack.
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See "Harness Connector Faces," to determine which type of connector is to be serviced.
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Use the proper pick(s) or tool(s) that applies to the terminal.
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The J 38125-A Terminal Repair Kit contains further information.
Repairing Short Circuits Caused By Damaged Wire Insulation
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Locate the damaged wire.
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Find and correct the cause of the wire insulation damage.
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For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of the wire (refer to the appropriate splicing
instructions for copper or shielded cable for the correct splicing procedure).
Splicing Copper Wire Using Crimp and Seal Splice Sleeves
Crimp and seal splice sleeves may be used on all types of insulation except Tefzel and coaxial to form a one to one splice. They are to be used where
there are special requirements such as moisture sealing. Refer to the appropriate section of the Service Manual to determine if the crimp and seal is
necessary. Crimp and seal splice sleeves are included in the J 38125-A Terminal Repair Kit.
Step 1: Open the Harness
If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam ripper" to cut open the harness (available from sewing
supply stores). The crimp and seal 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.
Step 2: Cut the Wire
Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the
location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 inches) away from other splices,
harness branches or connectors. This will help prevent moisture from bridging adjacent splices and causing damage.
Wire Size Conversion Table
Step 3: Strip the Insulation
If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire.
To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gauge. If
unsure about the wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the insulation is removed. Strip
approximately 7.5 mm (5/16 inch) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped
wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.
Step 4: Select and Position the Splice Sleeve
Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color-coded (refer to the Crimp and Seal Splice Sleeve
Chart).
