Sometimes while working on a car an accident can happen that makes more work for you. After dropping a wrench or a heavy component like an alternator you now have a split or broken wire to add to your repair list. When this happens, there is no need to have the car towed to the neighborhood mechanic. Just grab these simple tools and fix the broken wire yourself.
Things You'll Need
- 10mm wrench
- Heat-shrink tubing
- Hot-air gun
- Soldering iron
- Wire strippers
- Wire cutters
- 16-gauge wire
Remove the negative battery cable from the negative battery terminal using a 10mm wrench.
Cut out and remove the damaged wire and insulation using the wire cutters. Measure the distance between the wire ends. Cut a piece of 16-gauge wire that is 1 inch longer than needed. For example, if the distance between the wire ends is 3 inches, cut a piece of 16-gauge wire that is 4 inches long.
Remove ½ inch of insulation from all four of the wire ends using wire strippers. Cut two pieces of heat-shrink tubing 1 inch long. Plug in the soldering to allow it to come to temperature.
Grasp one wire end from the wire harness and pry open slightly to open the strands. Do the same on one end of the new wire. Place the two copper ends together. Tightly twist the strands in a clockwise direction.
Place the soldering iron tip on the wire splice for approximately five seconds. Touch the solder to the splice and feed the solder into the strands. As the copper heats, the melted solder will wick into the wire. Remove the solder and solder iron when the solder has fully wicked into the wire strands. Allow the solder to cool naturally.
Slide one piece of heat-shrink tubing over the solder splice. Use a hot-air gun to shrink the tubing around the wire. Remove the hot-air gun after the tubing has shrunk down to size. After the tubing has cooled, slide the second piece of heat-shrink tubing over the wire.
Continue with the second wire splice. Allow the solder connection to cool naturally. Move the second piece of heat-shrink tubing over the solder connection. Use a hot-air gun to shrink the tubing.
Connect the negative battery cable to the negative battery terminal.
- Photo Credit Hemera Technologies/PhotoObjects.net/Getty Images
How to Repair Electrical Wiring in an Engine Harness
Automobile wire harnesses are usually subjected to extreme conditions. The harness is fastened to the engine and chassis, which subjects the harness...
How to Fix a Broken Electrical Wire in a House
Home repairs sometimes require a professional, but hiring a professional is not always practical. Repairing wires in your home can be one...
How Do I Fix a Car Idle Problem?
A car idling problem can cause intermittent stalling and make it difficult for your engine to operate properly. A low idle may...
How to Fix a Broken Wire in a Wii Sensor Bar
Maybe one of your pets has an irresistible attraction to chewing on cords, or maybe you accidentally broke the wire yourself. The...
How to Fix a Broken Car Horn
A broken car horn is a bigger problem than some people might think. It can be annoying at times, but not when...
Jaguar Fuel Types
With advances in alternative fuel technology even at just a conceptual stage, Jaguar is readying itself for a future line of cars...
How to Fix Electric Guitar Wiring
So you take out your electric guitar to play one day, plug in the cable, turn your amp on and ... nothing....
How to Reconnect a Broken USB Cable
A USB cable consists of a number of wires attached to connector plugs at both ends. A cut in the end of...
How to Repair Car Seat Springs
After a few years of use the springs in the bottom of a car seat can become worn, bent, damaged and even...