PCM Wiring Loom Repair

[annihil8ted]

The last owner put in an oversized battery with some protruding fins around the top edge. They also didn't secure it down and it looks like over time, the shifting and rubbing has caused it to partially abrade through the PCM wiring loom. The outer most tape is gone and it's even partially gone through a few of the wire's sheathing.

I was chasing an electrical issue when I noticed this and I'm fairly certain this is the source with a few of my electrical gremlins. Any suggestions on how to repair? I'm pretty adept at soldering but not sure what's the best way to repair. Suggestions appreciated

 

[Chris]

Find appropriate sized wire, cut the damaged sections of the old wiring out, and solder / heat shrink in the new pieces. Then go over it with electrical tape or similar.

 

[cpwolf]

Agree with Chris, only suggestion I would have to add, is use wire harness tape like this
https://www.amazon.com/dp/B0821HLWCC?tag=wranglerorg-20

Regular electric doesn’t have a fabric feel, it gets all gooey and crap.

I learned the hard way

 

[annihil8ted]

Is it better to use solid or multi-strand wire in this case? And is the PCM wire gauge about 18?

 

[JMT]

The last owner put in an oversized battery with some protruding fins around the top edge. They also didn't secure it down and it looks like over time, the shifting and rubbing has caused it to partially abrade through the PCM wiring loom. The outer most tape is gone and it's even partially gone through a few of the wire's sheathing.

I was chasing an electrical issue when I noticed this and I'm fairly certain this is the source with a few of my electrical gremlins. Any suggestions on how to repair? I'm pretty adept at soldering but not sure what's the best way to repair. Suggestions appreciated

You do not want to solder. Soldered connections get brittle and break over time due to vibration. You want non-insulated seamless butt connectors staked on both sides and adhesive heat shrink. Like these from Sherco.

https://www.sherco-auto.com/products/300pc-us-made-non-insulated-seamless-butt-connector-kit

Or Dell City

https://www.delcity.net/store/terminals/butt-connectors/non-insulated-brazed-barrel/

 

[annihil8ted]

You do not want to solder. Soldered connections get brittle and break over time due to vibration. You want non-insulated seamless butt connectors staked on both sides and adhesive heat shrink. Like these from Sherco.

https://www.sherco-auto.com/products/300pc-us-made-non-insulated-seamless-butt-connector-kit

Or

https://www.delcity.net/store/terminals/butt-connectors/non-insulated-brazed-barrel/

This is a new one to me! I learned something today. But would these add a lot more bulk?

 

[JMT]

This is a new one to me! I learned something today. But would these add a lot more bulk?

I learned this from the master TJ guru. Ideally you stagger them in a loom. I realize they may all be in the same general area, so that may be difficult. How many wires need repair?

 

[chili_pepper]

Is it better to use solid or multi-strand wire in this case?

You're unlikely to find solid wire on your Jeep or any other vehicle, but most definitely in your house.

 

[cpwolf]

You do not want to solder. Soldered connections get brittle and break over time due to vibration. You want non-insulated seamless butt connectors staked on both sides and adhesive heat shrink. Like these from Sherco.

https://www.sherco-auto.com/products/300pc-us-made-non-insulated-seamless-butt-connector-kit

Or

https://www.delcity.net/store/terminals/butt-connectors/non-insulated-brazed-barrel/

These are new to me, I’ve only used crimp connectors with built in heat shrink on these tighter situations. I still use a separate heat shrink over the whole connector, overkill I’m told. Never seen these non insulated used, look like a good option .

 

[JMT]

Is it better to use solid or multi-strand wire in this case? And is the PCM wire gauge about 18?

Stranded, 22-18