Detroit Diesel — Clipped and Soldered Splicing Method
Repair & overhaul · Wiring harness
From a Detroit Diesel service manual — check it applies to your exact model before use.
Before you start
- No more than one strand in a 16 strand wire may be cut or missing.
Procedure
- Position the leads so one overlaps the other.
- Secure the leads with a commercially available clip and hand tool.
- Use a suitable electronic soldering iron to heat the wires; apply Sn 60 solder with rosin core flux to the heated wire and clip.
- Pull on wire to assure crimping and soldering integrity (14 AWG 45 lb, 16 AWG 27 lb, 18 AWG 20 lb).
- Loop the lead back over the spliced joint and tape.
Tools required
- Heat Gun Amazon
- Sn 60 solder with rosin core flux Amazon
- Wire Stripper Kent-Moore J-35615 Amazon
- Splice Clips Amazon
- Heat Shrink Tubing Raychem HTAT Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- 14 AWG withstand 45 lb (200 N)
- 16 AWG withstand 27 lb (120 N)
- 18 AWG withstand 20 lb (90 N)
Source: Detroit Diesel service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.