Performance Probe-The Ford Probe Forums

Wiring - Wiring Harness Terminal Repair Kit And Wire Splice Procedure
PUBLICATION DATE: October 15, 1999

• 1993-97 Probe

This TSB article is being republished in its entirety to include vehicles built through the 2000 model year.
ISSUE: A wire harness terminal repair kit is available for repairing electrical wiring harnesses. This kit allows the dealer to repair broken or corroded terminals instead of replacing an entire harness.
ACTION: If wiring repairs are required and you desire to purchase a kit, it can be obtained from the following source:

• U.S.A. - THOMAS AND BETTS WIRING SYSTEMS AND COMPONENTS: (800) 466-1986 OR (810) 493-1238
  CANADA - JOBBORN MANUFACTURING LIMITED: (800) 337-0823

REPAIR KIT BOX #1 AND #2 (PRICE: $295.00)
The kit consists of two (2) 60-drawer plastic cabinets with five (5) each of 96 different terminals.

• The terminals are machine crimped with a 102mm (4") "pigtail" wire that allows easy repair for the technician
  "Jiffy" splice seals are also included to provide a waterproof connection to protect the splice
  The kit comes with a unique, high compression crimping tool that ensures a solid connection

REPAIR KIT BOX #3 (PRICE: $110.00)
The kit provides electrical terminals for 1988 and newer Ford and Lincoln-Mercury vehicles which are not covered in Repair Kit Box #1 and #2.
The kit consists of a 60-drawer plastic cabinet with five (5) each of 59 different terminals.

• The terminals are machine crimped with a 102mm (4") pigtail wire that allows easy repair for the technician
  The kit includes adhesive-lined dual wall heat shrink tubing containing hot melt wax to provide a durable waterproof splice (*recommended for warranty repairs)

REPAIR KIT BOX #4 (PRICE: $208.00)
The kit consists of one (1) plastic cabinet containing five (5) each of 60 different terminals, each machine crimped to 102mm (4") of high temperature wire. It also consists of the following:

• Fourteen (14) gold-plated terminals for Electronic Engine Control (EEC), air bag, and Anti-lock Brake System (ABS) wiring repairs
  Eleven (11) European-style (Contour/Mystique) terminals

Wire Splice Procedure

Heat shrink tubing provided with Repair Kit Box #3 may be used for 16, 18, or 20 gauge wire only. For wire gauges larger than 16, a Deutsch Jiffy Splice must be used (available in Repair Kit Box #1 and #2).

Heat shrink tubing containing hot melt wax is included with Repair Kit Box #3 and offers a Ford-approved method for joining two (2) circuits. When properly used with a soldered circuit joint, this Ford-approved heat shrink tubing will provide a stable, low electrical resistance connection for years of service in any Ford or Lincoln-Mercury vehicle.

If an unreliable splicing method is used, the circuit joint may be unstable, resulting in variable resistance or a short circuit. Variable resistance can be the result of oxidation (corrosion) caused by air within the joint. A short circuit (signal leakage) is caused by either moisture on the circuit joint or a frayed wire coming in contact with another wire. Either situation may cause electrical systems to malfunction.

It is important to use heat shrink tubing containing hot melt wax over a soldered circuit joint to create a waterproof and airtight connection.

The following 5 Steps should be used when joining two (2) circuits using solder and heat shrink tubing containing hot melt wax:

• 1.)Strip 38mm (1.5") of insulation from Wire #1 and 19mm (0.75") of insulation from Wire #2 (Figure 1). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off end and restrip.
  2.)Twist and solder the wires (do not forget to install the heat shrink tubing first) (Figure 2). Use rosin core mildly activated (RMA) solder. DO NOT use acid core solder.
  3.)Form (bend) the circuit into a shape for sealing (Figure 3).
  4.)Re-position heat shrink tubing over splice (Figure 4).
  5.)Heat the entire length of the heat shrink tubing until the hot melt wax appears from both ends of the tubing (Figure 5).

OTHER APPLICABLE ARTICLES: None
SUPERSEDES: 99-6-3
WARRANTY STATUS: Information Only
OASIS CODES: 203000, 203200, 209000