TM 1-1270-476-30
2-9
2-5. CABLE AND WIRING HARNESS ASSEMBLY REPAIR (cont)
k. Slide heat shrinkable insulation sleeving
down over soldered contact and apply heat.
Insulation sleeving will form a snug fit after
shrinking.
l. Place wires in wire bundles. Secure
harness assembly using spot ties and
clamps.
m. Perform electrical test (1g above).
n. Have connector installation inspected.
END OF TASK
3. PREWIRED CONNECTOR REPLACEMENT
REMOVAL
a. Remove wire harness clamps and spot ties
as necessary to access wiring to prewired
connector being replaced.
b. Tag and stagger cut wires (TM 55-1500-
323-25) from connector being replaced.
INSTALLATION
NOTE
Replacement prewired connectors are
attached to wire harness using solder splices.
Splices must be staggered to avoid contact
with other splices and components.
c. Cut wires from replacement connector,
allowing 1/4 inch additional length than
defective connector wires for overlap.
NOTE
Stripped portion of wires must be long enough
to overlap inside solder sleeve. Thermoplastic
inserts must grip wire insulation.
d. Strip insulation from wire ends.
e. Tin wire ends.
f. Insert wire ends in solder splice.
CAUTION
When applying heat to solder splices, take
care to avoid damaging other components.
g. Using heat gun with reflector, shrink solder
splice.
h. Remove tags.
i. Place wires in wire bundle. Secure harness
assembly using spot ties and clamps.
j. Perform electrical tests (1g above).
k. Have prewired connector installation
inspected.
END OF TASK
4. UNSHIELDED CONTACT REPLACEMENT
REMOVAL
a. Remove wire harness clamps and spot ties
as necessary to access wiring to contact
being replaced.
b. Remove faulty contact from connector
using removal tool specified in table.
NOTE
Cut wire as close to contact as possible.
c. Cut wire from faulty contact.
INSTALLATION
d. Strip wire to proper length for insertion in
contact wire barrel.
e. Insert stripped end of wire into contact wire
barrel. Hold wire in position and check that
wire is visible through inspection hole.
