Preliminary Requirements

Procedure

1. SUBTASK 78-32-47-350-058 Remove the Contacts from the Damaged Wire(s)

   1. Refer to Figure.

   2. Remove the strain relief

      1. Remove the lockwire from the strain relief screws and the strain relief.

      2. Remove the screws and strain relief clamping bars from the strain relief.

      3. Remove the strain relief from the backshell and move it along the harness away from the backshell.

      4. Remove the tape from under the clamping bar locations.

   3. Remove the grounding ferrule from the backshell

      1. Remove the grounding ferrule from under the braided wire shields and move it along the harness away from the backshell.

      2. Do not damage the braided wire shields.

   4. Remove the backshell from the connector

      1. Remove the lockwire from the backshell nut and the backshell.

      2. Remove the backshell from the connector.

   5. Identify the contacts

      1. Put a piece of CoMat 02-002 ADHESIVE TAPE GENERALPURPOSE PAPER on the wire to which contacts are connected.

      2. Make a mark on the tape to identify the connector holes in which the contacts are installed.

   6. Remove the contacts from the connector

      1. Use theContact removal/insertion tool to remove the contacts from the connector.

   7. Remove the contact from the wire

      1. Remove the contact from the wire.

      2. Cut the wire as close as possible to the contact.

      3. Cut the end(s) of the wire back in to the wire bundle. Do not remove the wire.

2. SUBTASK 78-32-47-350-059 Install the New Wire(s)

   1. Refer to Figure.

   2. Apply tape to the damaged area of the wire bundle

      1. Put three layers minimum CoMat 02-187 ELECTRICAL INSULATINGTAPE around the wire bundle at the damaged area

   3. Cut the new wire

      1. Cut the new wire slightly longer than needed.

   4. Put the new wire in to position

      1. At both ends of the harness, push the end of the wire through the ferrule, the strain relief, the backshell, and through a hole in the shielding.

      2. Pull enough wire through for connection to the connector.

   5. Install the new wire

      1. Trim both ends of the wire to the length needed to attach it to the contacts.

      2. Fold the shielding back along the wire to match the shielding on the wire bundle.

      3. Weave the shielding from the new wire into the existing wire bundle shield.

   6. Attach the new wire to the wire bundle

      1. Attach the new wire to the wire bundle with CoMat 02-159 LACING TAPE.

      2. See Repair, VRS2125 (Repair-001) TASK 78-32-47-300-001.

3. SUBTASK 78-32-47-350-060 Install the Contacts on the New Wire(s)

   1. Refer to Figure.

   2. Prepare the wire

      1. Remove the insulation from the end of the wire so that the remaining insulation is against the aft edge of the pin.

      2. Make sure that you can see the bare wire through the inspection hole in the contact.

      3. Do not cut or nick the wire

   3. Install the contact on the wire

      1. Put the contact in the Contact crimping tool.

      2. Put the bare wire in to the contact.

      3. Make sure that you can see the bare wire through the hole in the contact and that the insulation is against the aft edge of the contact

   4. Install the contacts in the connector

      1. Install the contacts in the connector with the Contact removal/insertion tool.

      2. Push on the contacts from the front of the connector to make sure that they are fully installed.

      3. They are fully installed if they do not move rearward when you push them from the front of the connector.

      4. Remove the tape markers from the wires.

   5. Install the backshell on the connector

      1. Install the backshell on the connector.

      2. Tighten the backshell nut by hand plus one eighth turn with the connector pliers.

      3. Safety the backshell nut with CoMat 02-176 LOCKWIRE.

   6. Install the grounding ferrule

      1. Move the grounding ferrule toward the backshell and under the braided wire shields.

      2. Put the braided wire shields evenly over the grounding ferrule.

      3. Push the grounding ferrule in to the backshell.

      4. Shape the braided wire shields over the top of the grounding ferrule and along the outer jacket of the harness. The braided wire shields must end at the aft end of the strain relief.

   7. Install the strain relief on the backshell

      1. Put enoughCoMat 02-177 MASKING TAPE (GLASS CLOTH) on the electrical harness and over the ends of the braided wire shields so that the strain relief clamping bars will fit tight on the wire harness.

      2. It is not necessary for the clamping bars to fit tight against the strain relief.

      3. Install the strain relief on the backshell.

      4. Tighten the strain relief until firmly gripped connector pliers slip on the strain relief.

      5. Install the clamping bars on the strain relief ears with the screws.

      6. Torque the screws to between 12 and 15 lbfin (1 and 2 Nm).

      7. Safety the screws with the CoMat 02-176 LOCKWIRE.

4. SUBTASK 78-32-47-220-055 Examine the Completed Repair

   1. Visually examine

      1. Examine the completed repair to make sure all the requirements of this repair procedure are done.

5. SUBTASK 78-32-47-750-054 Test the Right C-Duct Electrical Harness

   1. Test the harness

      1. Refer to Testing-001 TASK 78-32-47-700-301.

6. SUBTASK 78-32-47-350-061 Identify the Repair

   1. Make a mark VRS2127 adjacent to the assembly numbers.

      1. Use CoMat 06-131 MARKING PEN of a color that contrasts.

Figure: Left C-Duct Electrical Harness Connector Replacement

Left C-Duct Electrical Harness Connector Replacement