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<blockquote data-quote="crash2" data-source="post: 1326746" data-attributes="member: 15940"><p>Now here is how I repair broken wires since this is a common occurance on the older toy wiring. It gets hard an brittle where its exposed then the insulation will crack and that just lets the stands of wire wiggle and break.</p><p>Remove the broken connector and peel out the sealed element around the wire. Once thats done use a pick of something along those lines and release the lock for the terminal and slide it out.</p><p><img src="http://rdsd.com/albums/album27/sam89.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p>Take the removed terminal and spread open the area that retains the wire with insulation around it.</p><p><img src="http://rdsd.com/albums/album27/sam90.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p>Once its spreadd open take the wire and bend it up 90 degrees</p><p><img src="http://rdsd.com/albums/album27/sam91.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p>Now take the wire and bend it torwards the spead open portion and back up 90 degrees. Continue to do this until the strands of wire break off. If you have done it correctly the strands of wire that are still retained on the terminal where the strands are crimped will be a nice sharp break.</p><p><img src="http://rdsd.com/albums/album27/sam92.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p>First take the sealed element and slide it down on the wire on the harness.</p><p>Now take the wire on the harness and cut it back a bit and remove about 1/8" of insulation. Now take the terminal and we will re-use the spead open portion that we recently spread open. There are a couple methods to crimp the spead open area of the terminal back down against the wire--one using a pair of needle nose pliers and carefully crimp the ears back down. Myself I like to use the factory way and I use whats called an F crimper. If done right the ears on the terminal will look the same as it did before. I also like to solder it to ensure a good solid contact. Sorry for the poor picture</p><p><img src="http://rdsd.com/albums/album27/sam93.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p>Shove the terminal back into the connector body and seal element and wala!!</p><p><img src="http://rdsd.com/albums/album27/sam94.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p></blockquote><p></p>
[QUOTE="crash2, post: 1326746, member: 15940"] Now here is how I repair broken wires since this is a common occurance on the older toy wiring. It gets hard an brittle where its exposed then the insulation will crack and that just lets the stands of wire wiggle and break. Remove the broken connector and peel out the sealed element around the wire. Once thats done use a pick of something along those lines and release the lock for the terminal and slide it out. [IMG]http://rdsd.com/albums/album27/sam89.jpg[/IMG] Take the removed terminal and spread open the area that retains the wire with insulation around it. [IMG]http://rdsd.com/albums/album27/sam90.jpg[/IMG] Once its spreadd open take the wire and bend it up 90 degrees [IMG]http://rdsd.com/albums/album27/sam91.jpg[/IMG] Now take the wire and bend it torwards the spead open portion and back up 90 degrees. Continue to do this until the strands of wire break off. If you have done it correctly the strands of wire that are still retained on the terminal where the strands are crimped will be a nice sharp break. [IMG]http://rdsd.com/albums/album27/sam92.jpg[/IMG] First take the sealed element and slide it down on the wire on the harness. Now take the wire on the harness and cut it back a bit and remove about 1/8" of insulation. Now take the terminal and we will re-use the spead open portion that we recently spread open. There are a couple methods to crimp the spead open area of the terminal back down against the wire--one using a pair of needle nose pliers and carefully crimp the ears back down. Myself I like to use the factory way and I use whats called an F crimper. If done right the ears on the terminal will look the same as it did before. I also like to solder it to ensure a good solid contact. Sorry for the poor picture [IMG]http://rdsd.com/albums/album27/sam93.jpg[/IMG] Shove the terminal back into the connector body and seal element and wala!! [IMG]http://rdsd.com/albums/album27/sam94.jpg[/IMG] [/QUOTE]
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