WIRING HARNESS AND CABLE REPAIR
STANDARD REPAIR PROCEDURES FOR WIRING HARNESSES AND CABLES
Do not allow dry-cleaning solvent, mineral spirits, or paint thinner to
be in prolonged contact with rubber components. These cleaners
cause leather, rubber, and synthetic materials to dry, rot, and lose
pliability making them unserviceable.
1. See Work Package 0028 for Standard Cleaning Procedures.
a. Clean cables and flexible hoses with soap and water.
All parts must be inspected with care. Replace parts if damage or wear exceeds allowable limits.
1. See Work Package 0028 for Standard Inspection Procedures.
a. Inspect all wiring harness assemblies and cables for broken leads, frayed insulation and
Check individual circuits for continuity.
Installation of Jumper Wire
Some wiring harnesses and cables are live (hot), even with MASTER
BATTERY switch in the OFF position. Disconnect the three battery
ground cable assemblies prior to disconnecting any wiring harness or
To substitute a jumper wire for a defective harness wire, tape jumper wire (using insulation
tape, item 40, WP 0173) to the exterior of the harness; do not disassemble the harness.
Disassemble the connectors as shown in the illustration (on the following pages of this work
package) that most closely matches your application and unsolder connectors (or cut off
crimped connectors) of the defective wire. Strip the insulation from end of the jumper wire to
the depth of solder well on contact insert, or approximately 1/8 inch when used with a terminal
assembly. Pass the jumper wire through the grommet-retaining nut and grommet, and solder
to the insert. On crimp-type connectors, pass the jumper wire through the connector body and
insulator or shell, and crimp to the terminal assembly. Reassemble the connector.
A cable that has been repaired by installing a jumper wire should be brushed or sprayed with
varnish to dry for approximately 24 hours before handling. The varnish is not a conductor of
electricity, so care must be taken to avoid over spraying the varnish on contact surfaces of wire
terminals, connector contacts, or similar parts where it will prevent the flow of electricity.
WP 0056 00-11