Automotive Service Excellence (ASE) A6 Electrical/Electronic SystemsGeneral Electrical/Electronic System DiagnosisMedium
A technician is inspecting a wiring harness that has been damaged by rodent activity, resulting in several exposed copper strands. The damage is localized to a small section of a non-critical sensor circuit. Which of the following is the MOST appropriate repair method for this type of damage?
- AWrap the damaged area with electrical tape.
- BApply liquid electrical tape over the exposed strands.
- CReplace the entire wiring harness.
- DCut out the damaged section and splice in a new wire using solder and heat-shrink tubing.
Show answer & explanationAnswer & explanation
Correct answer: D. Cut out the damaged section and splice in a new wire using solder and heat-shrink tubing.
For damaged wiring with exposed copper strands, a permanent, robust repair is required. Cutting out the damaged section and splicing in a new wire with solder and heat-shrink tubing creates a strong, corrosion-resistant, and insulated connection that meets industry standards for reliable electrical repairs.
Why the other options are wrong
- A. Electrical tape is a temporary solution and can fail due to heat, moisture, or vibration.
- B. Liquid electrical tape may provide some insulation but lacks the mechanical strength and long-term reliability of a proper splice.
- C. Replacing the entire harness is often excessive and costly for localized damage to a non-critical circuit.
Wiring Solder Repair
A method of permanently joining electrical wires by melting solder over the twisted or crimped wires, then insulating with heat-shrink tubing.
- Provides a strong, low-resistance electrical connection.
- Requires proper technique to avoid cold solder joints.
- Always insulated with heat-shrink tubing for protection.
Memory trick: Solder and Shrink: A Lasting Fix for Rodent's Gnaw.