B3000 DS Regular Cab 2WD V6-3.0L OHV (2002)
Wiring Harness: Technical Service Bulletins
Electrical - Wiring, Soldering and Crimping repairs
TSB: 09-024/05
2000-2006 B-SERIES TRUCK 2001-2006 TRIBUTE - ELECTRICAL - WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIP
NOTE:
This bulletin replaces 09-017/03. Please update your records accordingly.
BULLETIN NOTE
This bulletin supersedes the previous bulletin 09-017/03, issued on 11/3/2003. The APPLICABLE MODEL(S) / VINS and REPAIR PROCEDURE
have been revised.
APPLICABLE MODEL(S)/VINS
^
2000-2006 B-Series Truck
^
2001-2006 Tribute
DESCRIPTION
Wire harness repairs have been supported through the availability of complete harnesses and/or the availability of individual components - wire,
terminal, splices, heat shrink. This bulletin includes service information detailing wire folding, soldering and crimping techniques.
REPAIR PROCEDURE REPAIR VS. REPLACEMENT
The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to
this procedure are when:
^
The repair cost exceeds the cost to replace the wiring harness.
^
There are no component parts released to service the wiring harness.
RESTRAINTS RELATED WIRING REPAIRS
If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to
repair the circuit by a Service Bulletin or other Mazda publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses, they should be repaired using the solder and heat-shrink
repair procedure specified in this Service Bulletin. The Mazda Terminal Repair Kit (49L0-88-0A0) contains gold plated terminated pigtails (with white
insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are available thought MStore
at http://www.mstore2000.com.
SERVICE TIPS
Refer to applicable model year wiring diagrams for circuit information.
TWISTED WIRE CIRCUIT REPAIR
1.
The twisting should not be disrupted for more than 2" (51 mm). Twist the repaired wire in the same direction and with the same number of twists
as the original wiring. Reapply shielding on any shielded circuits.
2.
Stagger the repairs to minimize harness diameter and to maintain harness length.
3.
Leads that will not be used must be sealed with dual will heat shrink tubing and stowed. Silicone must not be used.
