Lay out the old harness with all the splices exposed, so that it can be used as a model for building the new harness.
Tag or otherwise identify all wires or cables.
Remove all cable connectors.
Inspection-Acceptance and Rejection Criteria
Shell and terminal assemblies:
Inspect for cracks, tears, cuts, chips, and gouges.
Inspect for condition of material and discard parts showing any sign of hardening.
Plug and receptacle assemblies:
Inspect for cracks, dents, bent inserts, cross threading, and damage that would impair their serviceability.
Repair or Replacement
General. Before repairing a harness, clean thoroughly of dirt and other accumulations with a brush and clean water. Dry
and perform the following inspection procedures:
Inspect harness for frayed areas.
Inspect individual leads for cuts and other evidence of excessive wear and for missing, damaged, and illegible circuit
number and part number markers.
Inspect all cable connectors as described in INSPECTION paragraph above.
Do not distort skirts of terminal when crimping to cable.
In plug and receptacle assemblies, plug all spare grommet holes with rod.
Replace frayed wiring.
Remove defective leads and replace, reusing cable connectors (refer to "c" below) where possible. Use spare harness
leads, if present, as replacement or cut a new length of cable of proper gage and assemble into the harness (refer to
ASSEMBLY paragraph below).
Remove damaged and defective connectors and install new connector parts as follows:
(1) Terminal-type cable connector:
(a) Strip cable insulation equal to depth of terminal well.
(b) Slide insulator over cable.
(c) Insert cable into terminal well, and crimp.
(d) Slide insulator over crimped end of terminal.