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TSB 08-06-00

Wire Splice Repairs

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Geno's Garage Truck Accessories

Date: Feb. 25, 2000

Models: 1989 1993 (AD) Ram Truck, 1994 2000 (BR/BE) Ram Truck

1989 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 2000 (AB) Ram Van/Wagon
1989 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 1993 (AD) Ram Truck
1989 1994 (AG) Daytona
1989             (AH) Lancer/Lebaron GTS
1989 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1989 1990 (AK) Aries/Reliant
1989 1990 (AL) Horizon/Omni
1989             (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 2000 (AN) Dakota
1989 1994 (AP) Shadow/Sundance
1989 1995 (AS) Town & Country/Caravan/Voyager
1990 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 1992 (BB) Monaco/Premier
1990 1994 (BD) Laser/Talon
1994 2000 (BR/BE) Ram Truck
1989 1992 (B2) Colt/Summit
1992 1995 (B3) Colt Vista
1989 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 1994 (B9) Colt/Summit
1998 2000 (DN) Durango
1992 1995 (ES) Chrysler Voyager (International Market)
1995 2000 (FJ) Sebring/Avenger/Talon
1996 2000 (GS) Chrysler Voyager (International Market)
1995 2000 (JA) Cirrus/Stratus/Breeze
1996 2000 (JX) Sebring Convertible
1993 2000 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1989 1992 (MJ) Commanche
1996 2000 (NS) Town & Country/Caravan/Voyager
1995 2000 (PL) Neon
1997 2000 (PR) Prowler
1996 2000 (SR) Viper/Viper GTS
1997 2000 (TJ) Wrangler
1999 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1989 - 1995 (YJ) Wrangler
1996 - 1998 (ZG) Grand Cherokee (International Market)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer

Discussion:
This bulletin provides a revised wire splice procedure and related parts. This is the only procedure approved by DaimlerChrysler Engineering. This procedure must be used anytime a wire splice repair is required.

Parts:
AR     05018395AA     Kit, Splice Band, (Refer To Usage Matrix)
Contains: One Splice Band, p/n 05018396AA, and Heat Shrink Tube
AR 05018526AA Kit, Splice Band, (Refer To Usage Matrix)
Contains: One Splice Band, p/n 05013243AA, and Heat Shrink Tube
AR 05018527AA Kit, Splice Band, (Refer To Usage Matrix)
Contains: One Splice Band, p/n 05013251AA, and Heat Shrink Tube
AR 05018528AA Kit, Splice Band, (Refer To Usage Matrix)
Contains One Splice Band, p/n 05018397AA, and Heat Shrink Tube
AR 05018620AA Kit, Splice Band
Contains: 200 Splice Bands, 50 Of Each Size
               200 Heat Shrink Tubes, p/n 04778570
               Instruction Sheet

NOTE: IF THE REPAIR REQUIRES ADDITIONAL WIRE ALWAYS USE THE SAME OR NEXT LARGER GAUGE WIRE.

Equipment Required:
Soldering Gun
Rosin Core Solder
Heat Gun

Repair:
1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.

2. Place a piece of sealant lined heat shrink tubing, p/n 04778570, on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.

3. Place the strands of wire overlapping each other inside of the splice band (Figure 1).

4. Using crimping tool, Miller p/n 8272, crimp the splice band and wires together (Figure 2).

 

5. Solder the connection together using rosin core type solder only (Figure 3).

CAUTION: DO NOT USE ACID CORE SOLDER.

6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 4).

 

Splice Band Usage Matrix

All crimped splices are to be soldered with rosin core solder only
Splices are to be covered and sealed by shrink tube 04778570
Splice band
package
required
Two Wire splices
...to One wire this size
22 20 18 16 14 12
One wire
this size...
22  05018395AA   05018395AA   05018395AA   05018395AA   05018526AA   05018527AA 
20   05018395AA 05018395AA 05018395AA 05018526AA 05018527AA
18     05018395AA 05018526AA 05018526AA 05018527AA
16       05018526AA 05018527AA 05018527AA
14         05018527AA 05018528AA
12           05018528AA
 
Splice band
package
required
Three Wire splices
...to Two wires this size
22 20 18 16 14 12
One wire
this size...
22 05018395AA 05018395AA 05018526AA 05018526AA 05018527AA Outside crimp
range
20 05018395AA 05018395AA 05018526AA 05018526AA 05018527AA Outside crimp
range
18 05018395AA 05018395AA 05018526AA 05018527AA 05018528AA Outside crimp
range
16 05018395AA 05018526AA 05018526AA 05018527AA 05018528AA Outside crimp
range
14 05018526AA 05018526AA 05018527AA 05018527AA 05018528AA Outside crimp
range
12 05018527AA 05018527AA 05018528AA 05018528AA Outside crimp
range
Outside crimp
range

Notes:

POLICY: Information Only


Thanks to Bob Bergevin for supplying this TSB information

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This page was edited on: May 3, 2004