Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page

6.2011 371 00 01 1(21)

Cable Repair
From build date 01.2007

Cable Repair
Note: Information is subject to change without notice.
Illustrations are used for reference only and may differ slightly from the actual vehicle
being serviced. However, key components addressed in this information are represented
as accurately as possible.

Contents
• “Definitions”, page 2
• “Terminal Construction”, page 2
• “Connector Housing”, page 4
• “Seals and Plugs”, page 8
• “Butt Splices”, page 10
• “Wires General”, page 13
• “Wires For Data Link Communication”, page 15
• “Grounding Points”, page 16
• “Soldered Joints”, page 17
Note: For special tools ordering instructions, refer to Tools Information, Function Group 08.

Note: For parts ordering, contact your local authorized dealer.

PV776-89026405 USA49561
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 2(21)

Cable Repair
Definitions
Connector housing The protective outer casing
around the terminals in a
connector. Also the protective
outer casing round the wires.
Connector An ordinary connector consists
of an connector housing with
internal terminals. Connectors
with various kinds of housings
(cases) surrounding the
insulators are also found.
Cavity A hollow space. This can either
be the space in which the
terminal is located, or a hollow
space for the demounting tool,
for taking the terminals apart.
Primary locking
Secondary locking
Sws
Locks the terminal into the
connector housing. This is
always separate for each
terminal. Located either on the
terminal or in the connector
housing.
The fastener that locks the
terminal into the connector
housing may be on the connector
housing or can consist of one or
more loose parts.
Single wire seal. A seal which
is crimped round the wire at the
insulation strain relief device,
and which seals between the
cavity in the connector housing
and the conductor.

Connectors, Terminals and Connector Housings

A connector is a detachable joint between two wire
harnesses. The connector consists of two connector
halves, which are joined together and locked to each other.
A connector half sometimes consists of a housing, seals
and terminals. One connector half contains pin terminals
and the other half contains mating socket terminals.
Housings can be considered male or female in gender.
Housings contain the opposite gender from their own.
Female housings normally contain male terminals and
male housings contain female terminals. Each terminal is
connected to a wire, generally by crimping, for the purpose
of transferring electrical current in the best possible manner.
The purpose of the connector housing is to protect the
terminal from unwanted electrical contact, ensuring that the
correct terminals are joined together, and that the halves of
the connector stay together.

Terminal Construction
There are many different designs of terminals. A general
description is given below.

Mating Section, Crimping Section and Insulation Strain Relief

Most terminals consist of three sections:
1 Mating section - (1), ensures electrical contact between
the terminals. Usually referred to as Male - Female.
2 Crimping section - (2) is the electrical joint between
the stripped section of the conductor (copper conductor)
and the terminal.
T3012838
3 Insulation strain relief - (3), relieves the crimping
section from mechanical stress. The insulation strain 1 Mating section
relief is placed over the insulating sheath of the wire.
This is normally found on terminals that are open and 2 Crimping section
uninsulated. 3 Insulation strain relief
The crimping section of the terminal and the insulation
strain relief are formed on the terminal by the crimping tool
at the same time. It is very important that the crimping
process is correctly done.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 3(21)

Size
The size of a terminal either refers to the conductor
area/gauge that the terminal is intended for, or the size of
the mating section between the pin and socket.

The size of the mating section is specified as the width or

diameter of the blade/pin section.

The designation for a terminal is written with the size first,

such as 2.8 blade terminal.

For eyelet terminals, it is the diameter of the hole that the

T3012839
size refers to. The size of the hole should fit the screw
which the terminal will be connected to.
Size of terminals
1 Conductor area/gauge
2 Size, mating section

Lock Tongue, Primary Locking

Most terminals have one or more tongues which serve
as locking devices and hold the terminal in place in the
connector housing.

The locking device is referred to as the primary locking

device, and each individual terminal has it’s own primary
lock. In some cases the primary locking is located on the
connector housing, please refer to “Connector Housing”,
T3012840
page 4 for a more detailed description.

It is important that the lock tongue is correctly angled Lock tongue

outwards, so that the terminal seats securely in the
connector housing.

• Single primary locking means terminals with one lock

tongue.
• Double primary locking means terminals with two lock
tongues.
In some cases, there is also a secondary locking device
located on the connector housing to provide further security
in retaining the terminals, please refer to “Connector
Housing”, page 4 .

Both primary and secondary locking devices must be

opened when the terminal is changed.
T3012841

1 Single primary locking

2 Double primary locking
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 4(21)

Embossing
Some male terminals and female terminals can be provided
with an embossed dimple or tension lug.

The function of the dimple is to hold the mating sections of

the terminals together, through mechanical retention force
between the male and the female terminals.

T3012842

Receptacle with dimple

Connector Housing
General
When the male and female connector housing are together and to ensure that the connector halves remain
connected together, they are referred to as connector together.
halves.
A connector housing for a female is referred to as a male
It’s the connector housing job to protect the terminal from insulator, and an insulator for a female is referred to as a
unnecessary contact and the environment. Also, in most female insulator.
cases, ensures that the correct terminals are connected

Coding
The connector halves are frequently coded to ensure that
they only connect to each other. This ensures that the
correct wires are linked together at each joint. This can be
done through coloration and/or through mechanical coding.

T3012843

Example of mechanical coding

Locking Between Connector Halves

Connector housing can frequently be locked together or
to a components.

There are two types of locking: active locking and passive

locking.
1 Active locking means that the lock must be released
before the connector halves can be divided.
2 Passive locking means that the connector halves must
be pulled apart with a certain amount of force.
When connector halves are divided the locking device must
be released.

T3012844

1 Example of active locking

2 Example of passive locking
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 5(21)

Contact Sides and Wire Sides of Connector Housing

The contact side is the side of the connector housing that
is joined together with the mating connector housing. The
contact side is also referred to as the front of the connector.

The wire side is the side where the wires go into the
connector housing. This is also referred to as the rear of
the connector.

T3012845

1 Contact side
2 Wire side

Connector Housing Cavities and Position Numbers

Cavities are the hollow spaces in the connector housing
where the terminal is located, and where a disassembly tool
can be inserted. The cavity openings on the contact sides
of the connector housing have easily identifiable shapes,
that are each designed to suit a different type of terminal.

Each cavity is numbered. The pin number is found on

the wiring diagram as the position number. Example:
designation SW3 means position 3 in connector SW.

In some connector housing, there are cavity openings that

are only intended to be used as disassembly grooves.
Cavity openings are found with up to four disassembly
grooves.
T3012846

1 Cavity
2 Position number
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 6(21)

Reinforced Moisture Protection

Some connector housing can have reinforced moisture
protection, by means of gaskets, rubber sheaths on wires,
plugs in unpopulated cavities and seals around the crimped
sections of the insulation strain relief on the terminals.

Note: All cavities must either be used or plugged.

T3012847

Example of moisture-proof joint

1 DIN connector housing
2 Moisture-proof joint
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 7(21)

Locking of Terminals in Connector Housing

The terminals are retained inside the connector housing by
various kinds of locking device, to prevent the terminals
from being pressed out backwards during connecting.

The locking system can consist of primary locking and/or

secondary locking devices.

Both primary and secondary locking devices must be

opened/released when the terminal is changed. T3012848

Primary locking: Most of the time, primary locking Primary locking on connector housing
is located in the terminal, please refer to “Terminal
Construction”, page 2 for a more detailed description.
In some cases, primary locking can be provided on the
connector housing.

Secondary locking: If secondary locking devices are

provided, they are always installed on the connector
housing and lock several terminals at once. Secondary
locking, provides strain relief and maintains the terminals in
place.

There are many different secondary locking variants. The

following illustrations show some examples of secondary
locking.

T3012875

Secondary locking by means of the connector

T3012849
housing strain relief

Secondary locking by means of a lid

T3012901

T3012900
Secondary locking, cavity
Secondary locking
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 8(21)

Seals and Plugs

Seal for Terminals in Connector Housing
Note: Always use a seal of the correct size for the wire
and connector cavity.

Note: Always use the correct sized plug in unused

cavities in the connector housing.

Seals are used in places where the connector housing are

exposed to corrosive environments, where there’s a risk of
water ingress into the connector housing cavities.

The rubber-based seals prevent corrosion and maintain

their sealing properties even when subjected to strong
T3012906
vibration and temperature cycles.

The seals are crimped around the wire by the insulation Seal
strain relief, and seal against the cavity in the connector
housing.

Seals are found in various colors and sizes.

A seal should be used when a hole is seen in the crimp

area of the terminal as shown.

T3012851

If there is a “hole”, a seal should be used

Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 9(21)

Plugs
Plugs are used to block empty (unpopulated) cavities in a
moisture-proof connector housing.

The plug should be inserted flush to its end position, or if

there is no end position, about 3-5 millimeter below the
surface.

T3008967

A plug is more or less the same as a seal, but without a

hole for the wire.

Plugs are found in various colors and sizes.

T3012852

Plug
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 10(21)

Butt Splices
Butt splices function as a mechanical joint conductor when
connecting two wire ends together. The difference is that
it is more difficult to undo the joint made by the butt splice.
Butt splices are crimped onto the end of the wires.

T3012853

Butt splice

A butt splice consists of two sections:

Crimping section — (1), the electrical link with the stripped

section of the conductor (copper wire).

Center stop — (2), used to center the stripped wires in a

blind insert for more uniform crimping

An insulated butt splice also has an insulating sheath

(3) which protects the butt splice from unwanted electrical
contact. The sheath is shrunk onto the wires insulation by T3012854

means of a hot air gun.

Butt splice
The crimped section of the butt splice is formed in the jaws
of a hand crimp tool. It is very important that the crimping 1 Crimping section
process is correctly done. 2 Center stop
3 Insulating sheath

No more than two wires can be connected to each end of

a butt splice.

T3012855

Butt splice with three wires connected

Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 11(21)

Crimping Tools, Terminals and Butt Splices

General
Crimping is a method for creating electrical connections.
The crimping section of the terminal is pressed around the
conductor with such pressure that it forms a homogenous
(gas-tight) seal with the metal in the conductor.
When correct tools are used, it is a quick and easy task to
attach a terminal onto a wire, and makes a more reliable
and stronger joint than a soldered joint, for example.

Design
A crimping tool is designed to suit various types of terminals,
by both the design of its press jaws and the press force
it generates.

T3019335

Crimping
The reason for using crimping tools, is to create cold flow
between the terminal and the wire. Crimping has to be
carried out under extremely high pressure to generate cold
flow. For this reason, it is extremely important that a quality
crimping tool is used for each terminal.

T3012862

Cold flow between terminals and conductor

Correct Crimping of Terminals

The wire must be stripped and inserted into the terminal in
the correct manner, to give a correct crimp:
1 The stripped length of the conductor should only be
compressed under the crimping section of the terminal. It
must not project too far in front of, or behind the crimping
section.
T3012863

2 The insulated section of the wire should only be

compressed under the strain relief section of the Correctly terminated terminals
terminal. It must not project too far in front of, or be
1 Crimping section
displaced behind the strain relief section.
2 Strain relief section
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 12(21)

Examples of Poor Crimping

Incorrect Dimension of Crimping Section on the Terminal
A terminal with a crimping section that is too small can not
surround the copper conductor in the wire.

A terminal with a crimping section that is too large can not

compress the copper conductor sufficiently to cause cold
flow.
T3012864

Problems occur when crimping has been done incorrectly,

or a terminal has been used/applied incorrectly, example; Crimping section which surrounds:
• The application required a sealed terminal and an 1 Too large conductor area.
unsealed terminal was used instead.
2 Too small conductor area.
• A terminal of incorrect size for the conductor area has
been used.
• The terminal has been crimped in the wrong cutout in the
jaws of the hand crimp tool.
• An incorrect tool has been used.
Note: Incorrect crimping causes poor contact, which
can cause contact failure, an open circuit, or intermittent
(irregular) faults which can be difficult to locate and discover.

Twisted Copper Conductors

Do not twist the stripped end of a wire before crimping. wires could be twisted straight again, and the wire area
When a copper wire is twisted, it increases in thickness. In would reduce in size. This would allow for the connection to
other words, it assumes a greater wire area in the twisted become loose due to a loss of crimping force and a contact
section. As time passes, there is a risk that the copper fault could occur.

Incorrect Matching of Conductor to Terminals

1 Conductor incorrectly inserted — The conductor is
not inserted far enough to ensure current transfer and
strain relief.
2 Stripped end of conductor is too short — In this case,
the stripped end of the wire is too short to ensure current
transfer, at the same time part of the insulation is trapped
beneath the crimping section.
3 Wiring too far back — If the stripped section of the
wire is too long, and the conductor is correctly aligned in
relation to the crimping section, the strain relief will not
surround enough of the wire.
4 Wiring too far forwards — If the stripped section of the
wire is too long, and the conductor is correctly aligned in
T3012865
relation to the strain relief section, the copper conductor
will project past the end of the crimping section.
Terminal with:
5 Projecting copper conductor — Projecting copper
conductors can lead to short circuits with adjacent 1 Insufficiently inserted conductor.
conductors. 2 Stripped section of conductor too short.
3 Conductor too far back.
4 Conductor too far forwards.
5 Projecting copper conductor.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 13(21)

Wires General
Introduction
It is important that the wires in a vehicle are properly • That the wiring is installed in a way that protects it from
chosen with the purpose in mind, and installed in a correct mechanical damage.
manner. It is also important that it should be easy to
The electrical wiring diagrams are a considerable help
distinguish separate wires by means of colors etc. to
when you change or repair any circuit, please refer to the
facilitate identification and fault tracing of circuits. The
service information in Function Group 37.
following are some important points to consider when a
circuit is changed or extended:
Note: When you replace any wire, always use the
• That the gauge is correct. same type of wire as the original, i.e. the correct length,
• That the shielding protection on wires that transmit insulation, gauge and preferably the same color.
signals, such as between control units, is intact.
• That the circuit colors are maintained.

Conductor Area
It is important that the gauge is at least as large after a repair
as it was prior, since the current carrying capacity of the
circuit depends on the conductor area/gauge. If the wiring
diagram books can not give you any information about the
conductor area/gauge, it can be estimated by measuring
the diameter of the stripped section with a caliper gauge.
Then read the table to get an approximate estimation of
the conductor area/gauge. T3012856

Note: The conductor area and diameter always refer to Conductor diameter measurements
the metallic conductor in a wire.

Conductor Area

Diameter mm Conductor area

(in) mm² (in²)
0.6 (0.02) 0.3 (0.01)
0.8 (0.03) 0.5 (0.02)
1.0 (0.04) 0.75 (0.03)
1.1 (0.04) 1.0 (0.04)
1.4 (0.06) 1.5 (0.06)
1.8 (0.07) 2.5 (0.1)
2.3 (0.09) 4.0 (0.16)
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 14(21)

Replacement Wire Sizes

The size of wire used when installing accessories or Wire Gauge
repairing existing electrical items is dependent on the length
of the wire and power requirements of the accessory. The American Wire SAE mm² (in²) DIN mm² (in²)
chart below can be used to determine the proper wire size Gauge (AWG)
for 12 volt systems. 4/0 103.0 (4.1) 120.0 (4.7)
To use the chart, mark the appropriate length for the wire 3/0 81.0 (3.2) 95.0 (3.7)
being installed in the m/ft column. Also mark the rating in the 2/0 62.0 (2.4) 70.0 (2.8)
amps/watts column. Then draw a line connecting the mark
in the length column to the one in the rating column. The 0 50.0 (2.0) 50.0 (2.0)
point where the line crosses the wire size column is the size 2 32.0 (1.3) 35.0 (1.4)
of the wire required. If the line crosses the wire size column
4 19.0 (0.7) 25.0 (1.0)
between gauge sizes, round up to the next larger size.
6 13.0 (0.5) 16.0 (0.6)
If replacing a wire and the amperage of the circuit is not
known, it can be measured using an ammeter. 8 8.0 (0.3) 10.0 (0.4)
10 5.0 (0.2) 4.0 (0.2)
12 3.0 (0.1) 2.5 (0.1)
14 2.0 (0.08) 1.5 (0.06)
16 1.0 (0.04) 1.0 (0.04)
18 0.8 (0.03) 0.75 (0.03)
20 0.5 (0.02) 0.5 (0.02)
22 0.35 (0.01) 0.35 (0.01)
24 0.22 (0.009) 0.22 (0.009)

• AWG: America Wire Gauge (US Standard)

• SAE: Society of Automotive Engineers (US Standard,
Metric)
• DIN: Deutsche Industry Norm (European Standard,
Metric)

W3001006

Chart for calculating relationship between wire

length, gauge and amperage/wattage

EXAMPLE:
A 12 volt hydraulic pump motor is rated at 20 amps.

The complete length of the circuit (power and ground sides)

is approximately 6 meters (20 feet).

A line drawn from 20 on the length column to 20 on the

rating column crosses the wire size column at the 8.

This indicates that the minimum wire size for the application
is 8 gauge.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 15(21)

Signal Transfer Wires

Wires for signal transfer are frequently protected against
interference by being arranged as a twisted pair, or they
have a protective shield. It is very important that the
interference protection of a wire be intact or arranged after
replacement or repair.
A twisted pair must be twisted at the same pitch as the
original wires, to maintain interference protection. For
further information please refer to “Wires For Data Link
Communication”, page 15.
On a shielded wire, it is important that the shield does not
T3012857
come into contact with the conductor it protects, that it is
intact for the entire length of the wire, and that the shield is
1 Twisted pair signal wire
terminated at the same place and in the same way as the
replaced wire. 2 Shielded signal wire

Wire Runs
When a wire is installed, the original wiring route should The wiring must be at least as long as the original wiring.
always be followed, and the wiring should be secured in the
same manner. The wire should be routed in such a way that
there is no risk of mechanical damage. No sharp ends must
be left projecting outside the tie wraps.

Wires For Data Link Communication

The SAE J1587 and SAE J1939 data links are data
communication wires. Both types of wire have twisted pairs
for interference protection.
When the data links are repaired, the same twisting pitch
must be maintained. Repairs must be done in the same
way as other wires, in other respects.
Note: For proper operation, it is important that the twist
pitch is maintained when data link communication wires
are joined.
Note: Use wires with the same conductor area/gauge,
color and grade as the originals.

The wires can be lengthened, but must not exceed a total

Note: The wire can be lengthened, but must not exceed
length of 40 meters (131 feet). The new wires must be
a total length of 40 meters (131 feet).
of the same type and the wires must have the same twist
pitch as the old ones.

SAE J1587 Data Link

SAE J1587 data link, is used for diagnosis in the vehicle
and transmits data at 9600 bps.
The wires are twisted with a twist pitch of 30 turns/meter
(33 turns/yard).
Note: SAE J1587 data link has a twist pitch of 30
turns/meter (33 turns/yard).
Lengthening of SAE J1587 data link wires can be done at
any point along the length.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 16(21)

SAE J1939 Data Link

SAE J1939 data link is mainly used for the vehicle drivetrain,
and transmits data at 250,000 bps.
The wires are wound at a pitch of 40 turns/meter (44
turns/yard).
There is a resistor at each end of the control link, that are
either mounted in the wiring itself, or built into the connected
control unit.
Note: SAE J1939 data link is twisted with a twist pitch of
40 turns/meter (44 turns/yard).
SAE J1939 data link wires must be lengthened at one end
of the wires harness, and the resistors located there must
be moved to the end of the extension.
It is possible to join new control units onto the data link.
There must be a distance of 0.3 meters (1 foot) between
each joint (stub) and the length of each stub must not
exceed 1 meter (3.3 feet). It is NOT permissible to join one
stub onto another stub. A stub must always be connected
to the original wiring harness.

Grounding Points
The grounding points are very important components in the • When multiple wires ground on the same point, make
electrical system of a vehicle, since all the voltage levels in sure each wire is rotated around the joint like a fan. (Not
the subsystems are referred to the grounding points, as 0 stacked)
volt. If there is a ground point suspected to have a faulty
A faulty grounding point can lead to effects in systems and
connection, the electrical system will be adversely affected.
functions which would not at first appear to be related to a
Several circuits are frequently joined together at the same ground fault. These faults can be very difficult to find.
grounding point, which means that several functions and
systems will be affected by the quality of the grounding
point.

It is thus very important that the electrical connection at

each grounding point is correct, which means that:
• There is no paint or dirt on the contact surface between
the terminal and the grounding point.
• There is no corrosion on the contact surface between
the terminal and the grounding point.
T3012866
• The connected terminals are correctly crimped.
• Nuts and screws are correctly tightened. Example of a threaded fastener as an grounding point.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 17(21)

Soldered Joints
General Notes About Soldering
Soldering is a method that is relatively easy to do. No If soldering is to give good contact and durability, it is
expensive equipment is needed and the conductor area important that the contact point is completely free of dirt,
is not so critical. oxidation, grease, paint etc.

The disadvantage of soldering is uneven quality. Poor

results can be obtained because of contamination at the Note: Avoid soldering at points where the current flow
contact points. is high. The solder joint may fail due to excessive heat
from current flow.

Soldering Quality
The factors affecting the quality of a soldered joint are the
choice of solder, flux and soldering tool, and how the joint
is located and made.
It is common for the wire to be heated so much that the
insulation is damaged and/or melts. In addition, the solder
can flow too far up the wire. If this happens, the wire
becomes hard and brittle, and the risk of wire breakage
increases.
While the wire should not be heated up too much, it must be
warm enough at the soldering point to avoid creating a “dry”
joint. If a dry joint is created, the electrical and mechanical
contact will be very poor, causing contact failure, open
contact or intermittent faults. These faults can be very
difficult to discover and pin point, since the soldered joint
will be covered by insulating shrink tubing afterwards.

Soldering Tools
There are various kinds of soldering tools. The most which allows the power and temperature of the soldering
common is the temperature regulated soldering station, iron to be regulated.

Solder Wire
It is very important to use rosin core solder containing a
good quality flux preparation. Note: Do not use solder with aggressive (acid-based)
flux. This can cause oxidation and contact problems.

Finishing
It is important that the soldered joint is insulated and
protected from unwanted electrical contact and mechanical
damage once it is finished.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 18(21)

Wire Splice, Solder and Seal

You must read and understand the precautions and
guidelines in Service Information, group 30, "General
Safety Practices", before performing this procedure. If you
are not properly trained and certified in this procedure,
ask your supervisor for training before you perform it.

Note: Wiring terminal and connector repair requires the use

of proper terminals (Packard, JAE, etc.) and specialized
tools. The following procedures are for general wiring
repairs only.

Note: Do not solder Deutsch style terminals. Soldering is

not required or recommended to keep the terminal secured.

Do not use acid core solder. When replacing wires use the
correct wire size (see “Wires General”, page 13). Secure
each harness or wire in place to prevent chafing or damage
to the insulation due to vibration. Never replace a wire with
one of a smaller size or replace a fusible link with a wire
of a larger size.

When soldering wiring always use rosin flux solder to bond

the splice. Use sealant shrink tubing to cover all splices
or bare wires.

It is very important when soldering electrical terminals

to obtain a good soldered joint. Use a quality soldering
iron such as a Weller Model 440D or equivalent. A good
quality soldering iron will offer dual heat in a medium range
(145/210 watts). Use Kester alloy SN60, Flux-44 Rosin,
0.80 mm (0.032 in.) maximum diameter or equivalent.

W3000568

Fig. 1 Wire splicing

1 Solder
2 Soldering iron
3 Heat shrink tubing with sealant
4 Wires twisted

Soldering Procedure
1
1
Clean and tin the soldering iron tip.
2
2
Clean the terminal to be soldered.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 19(21)

3
3
Strip the wire as necessary to fit the terminal. Do not cut
or nick the wire when stripping.

W3000569

1 Strip as necessary
2 Wire
4
4
Slide a piece of sealant shrink tubing onto the wire.
5
5
Insert the wire in the terminal and, with a pair of crimpers
(as recommended by the connector manufacturer),
squeeze the small tabs onto the wire insulation. Not all
types of terminals have these tabs. Be certain to use the
crimpers recommended by the connector manufacturer.
With a blunt instrument, form the bare wire so that it will
lay against the soldering area of the terminal.
6
6
Using the soldering iron, apply heat to the outside of the
terminal while holding the solder on the wire on the inside
of the terminal. When a sufficient amount of heat has
been transferred from the gun through the terminal and
into the wire, the solder will be melted by the wire. Melt a
sufficient amount of solder on the wire and withdraw the
solder and the tip of the iron.

NOTE: Do not hold the terminal with pliers or anything

W3000571
metal during the solder operation, as heat will be
1 Solder conducted away from the terminal.

2 Tabs (crimp over wire insulation)

3 Wire
4 Soldering iron
5 Terminal
7
7
Slide the sealant shrink tubing over the soldered
connection, making sure all exposed wire is covered.
Heat the tubing with a heat gun to shrink. Shrink until the
tubing is tight around the wire and the sealant is visible
out of both ends of the tubing.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 20(21)

Wire Splice, Crimp and Seal

You must read and understand the precautions and
guidelines in Service Information, group 30, "General
Safety Practices", before performing this procedure. If you
are not properly trained and certified in this procedure,
ask your supervisor for training before you perform it.

Note: Wiring terminal and connector repair requires the use

of proper terminals (Packard, JAE, etc.) and specialized
tools. The following procedures are for general wiring
repairs only. Always use properly sized wire when making
wire repairs. See “Wires General”, page 13.

Note: For crimp and seal repairs, use only splice or terminal
connections with heat shrink covering. If non-heat shrink
connectors are used, a separate piece of heat-shrink tubing
must be used to seal the connection.

1
1
Remove wiring insulation approximately 10 mm (3/8 inch)
from the end of the wire.

W3002878

2
2
Determine the proper size splice connector for the wire
being repaired. Install each end of the wire into the splice
until the wire hits the stop.

W3002875
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 6.2011 371 00 01 21(21)

3
3
Insert the connector into the proper anvil on the crimping
tool and crimp. Gently tug on the spliced connection to
be sure the wire is secure.

W3002876

4
4
Heat the splice connector to activate the heat shrink.
Look for sealant at each end of the connector as evidence
of a good application.

Note: Do not use an open flame to apply heat shrink.

W3002877