I need to extend the crank sensor wire - ideas?

[76_TypeLT]

The crank sensor wire is considerably too short for my setup, which is odd since most wires are way too long on my harness.

I figure I have two routes I can take. The first route, which sounds like the more legit route, would be to create my own extension with the correct connectors, terminals and wires. I am not sure I can get a male and female connector, however. I know I can get the female connector.

The second route would be to simply extend the three wires via splicing/soldering in new wires. It's not a terrible option since the splices would be hidden. If I go this route, what is the PROPER way to splice in some new wires?

Any ideas on how to best proceed?

 

[supwicha]

Assuming the wiring is not shielded, soldering in an extension may be an option for you. Don't even think about using wire crimps for this process.

You'll need the proper gauge of wire, rosin solder (not acid core), and heatshrink tubing. You'll want each of the segments to be the exact same length when the ends are stripped off.

Install sufficient amount of heatshrink FIRST, but keep it away from the heat of the splice. I normally will not twist the ends of the segments but rather push each of the opposing ends together.

Then while holding the splice at the center, twist the right side together to make it wrap. Then using your right hand, hold the center of the splice again (the half you just twisted), the rotate the left half of the splice the opposite direction. Then solder and heatshrink. This method usually results in the splice being close to the same thickness and does not leave any sharp strands of wire to poke through your heatshrink. If you use the "X" method of twisting, depending on the gauge of the wire, it will usually leave sharp wire strands they may poke through the heatshink and ground out or come in contact with another circuit. This method is also what most OEM's recommend as well.

Here is a link that demonstrates this method. About the 3:30 point in the video shows the process.

https://www.youtube.com/watch?v=Q9G9gaokqvM

 

[badazz81z28]

I personally prefer the heat shrink solder splice. All you do is heat it, the shrink shrink to hold it in place and the solder melts. We use these in the AF on test equipment.

http://www.amazon.com/Shrink-Solder-Sleeve-Crimpless-Connectors/dp/B00IEFOCRK

 

[Madmike72]

There's nothing wrong with extending/shortening wires to make your harness fit better. To me soldering and shrink wrapping is the only way. A lot of guys will tell you your going to add resistance to the circuit and screw up the signal. This isn't true if you do it correctly. Adding a big pooty crimp on plastic butt connector can add resistance, but a properly soldered connection will not. If you lack experience soldering it's easy to practice on a bench and get the hang of it quickly. One of the biggest tips for beginers is to get a dab of solder on the tip of you soldering iron to get things started quickly.

 

[76_TypeLT]

thanks guys, I know the wire is 22 gauge so I will get some of that and do some practicing before I solder in the new wires.

Re: the heat shrink solder splice - I learn something new everytime I post on this site. I've never seen those before but they look really interesting.