How should a technician best repair a broken wire in a harness?

To ensure a reliable and lasting repair, the best approach to fixing a broken wire in a harness is to crimp and solder. Crimping provides a mechanical connection that can withstand vibration and movement, which is particularly important in automotive environments. The mechanical bond established by crimping is often stronger than twisting wires together.

When soldering is added to this process, a solid electrical connection is formed while also insulating the joint against further humidity and corrosion. Soldering effectively fills gaps in the metal, creating a seamless conductive path that ensures optimal electrical connectivity.

This combination of crimping and soldering not only offers strength and durability to the repair but also adheres to good practices in wire management and electrical integrity. By contrast, simply twisting and taping wires might not provide a secure or lasting solution, especially in a high-motion environment. Wire nuts, while good for connecting multiple wires in some applications, are not practical for individual wire repairs in automotive harnesses. Replacing the entire harness can be unnecessary and more costly when effective repair methods are available.