How to Repair Automotive Wiring

Automotive wiring can become damaged and will need to be repaired over the lifetime of a vehicle. You can repair wiring in multiple ways; however, automotive industry standards dictate the proper way to repair damaged wire is to solder the broken pieces together to create a strong bond that is equal to the strength of new wiring.

Things You'll Need

  • Safety glasses
  • Socket and ratchet
  • Heat-shrink tubing
  • Wire trimmers
  • Soldering iron/ gun
  • Rosin-core solder
  • Heat gun
  • Put on the safety glasses. Disconnect the positive and negative battery cables from the vehicle's battery using the socket and ratchet.

    The battery is often located under the hood near the headlights.
    The battery is often located under the hood near the headlights.
  • Place a piece of heat-shrink tubing over either side of the broken wire and slide as far away from the break as possible.

  • Trim back the remaining protective coating with the wire trimmers and provide about an inch of bare wire on each end of the break, then overlap and twist the wire together, creating a strong connection.

    Wire strippers remove the protective coating from wires.
    Wire strippers remove the protective coating from wires.
  • Heat up the soldering iron and solder over the twisted wire. When done correctly the heat will cause the solder to wick into the wiring, creating a strong joint. Allow to cool and provide a gentle tug to the wire to ensure a good solder.

    Soldering iron produces high heat at the tip.
    Soldering iron produces high heat at the tip.
  • Slide the heat-shrink tubing up and over the bare wire joint and use the heat gun to shrink the tubing, effectively creating an air-tight seal.

    A heat gun is similar to a hair dryer.
    A heat gun is similar to a hair dryer.