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TSB 08-06-00

Wire Splice Repairs

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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

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