About I-CAR - Current Events/News: e-newsletters: Advantage Online: October 16, 2006

Figure 1 - The splicing kit contains all that is needed for properly splicing wires, including the crimping tool.

Figure 2 - The four different size splice bands included in the kit are for splicing different wire gauges.

Figure 3 - The crimping tool has a crimping nest for each of the four splice band sizes.

Figure 4 - The heat shrink splice sleeves look and act like regular shrink tubing, but are lined with sealant to properly seal the splice when heated.

This video shows the order of repairs to Chrysler Group restraint system wiring.

Click on the image to start the video.

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RESTRAINT SYSTEM WIRING REPAIRS FOR CHRYSLER GROUP VEHICLES

Add the Chrysler Group (Chrysler, Dodge, Jeep) to the list of vehicle makers allowing the splicing of restraint system wiring harnesses. An article last year discussed the General Motors procedure.

Previously it was a general recommendation for Chrysler Group vehicles to replace the entire instrument panel wiring harness whenever wires were damaged. That is no longer the case. Quality production engineers reviewed the wire splicing procedure that was already in place for other circuits and deemed it sound for safety circuits, including restraint system wiring.

It is important, especially with restraint system circuits, to use the recommended splicing kit and procedure. The procedure involves not only crimping the wires together, but also soldering the crimped connection before slipping on a special shrink tube splice sleeve that contains a sealant. The purpose of the crimp is to create a mechanical bond, which is then followed by a solder bond, and finally the sealant. This allows the crimp to pass pull tests 100% of the time. In other words, the splice should perform as good or better than the original wire and be safe from corrosion or shorting.

There is no limit on the number of splices that can be made in one harness, such as when a harness is cut by sharp metal in a collision. Multiple adjacent splices should be offset from each other.

As is the case with all other restraint system wiring repairs, pigtails on such parts as airbag modules and the clock spring should not be spliced. The approved splice procedure is for harness-side repairs only.

The splice kit (part number 05073029AA) includes splice bands, a crimping tool, heat shrink splice sleeves, and tie straps (see Figure 1). The kit is available from Chrysler Group dealerships.

There are four different size splice bands (see Figure 2). These are color-coded on the packages. The four colors correspond to a chart on the inside lid of the kit that indicates which size to use when making two or three wire splices, depending on the wire gauge.

The crimping tool has four nests for the different size splice bands (see Figure 3). The tool also has a locking ratchet mechanism in the handle that keeps the tool from being reopened until the proper amount of pressure has been applied to the splice band. This ensures that just the right amount of pressure is applied to the splice band.

The splice sleeves that contain the sealant actually look more like shrink tubing than other types of splice sleeves (see Figure 4). But regular shrink tubing should not be used. This tubing is lined with the sealant that oozes out when heat is applied.

To repair damage to Chrysler Group restraint system wiring, follow this procedure in the order listed (see Video).

Damaged restraint system connectors present another issue. The Chrysler Group is beginning a slow rollout of replacement connectors, but at this time only a few are available and only for 2007 models. To identify connector repair kit applicability and availability, follow this link: http://dto.vftis.com/mopar/disclaimer.asp

The connectors that are available are only for airbags that use sodium azide as the propellant, such as driver and passenger airbags. When these so-called "hot" airbags deploy, the connectors are often burned in the process, requiring connector replacement.

The recommendation is that if a connector is damaged, and a replacement connector is available, splice in a new connector. If a replacement connector is not available, replace the entire wiring harness. The Chrysler Group does not endorse the use of recycled connectors.

Restraint system wiring repairs are allowed by several vehicle makers, and now that list includes the Chrysler Group. Wire splice repairs can be made to restraint system circuits on Chrysler, Dodge, and Jeep vehicles. However, the wire splices must be done using the procedure described in this article.

For comments or suggestions on the Advantage Online, please contact I-CAR Senior Instructional Designer Bob Jansen at bob.jansen@i-car.com.

Current Events/News: Advantage Online: 2006 Archives