Hummer H2. Manual - part 1269

13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness 

covering. Use a winding motion in order to cover the first piece of tape.  

SPLICING COPPER WIRE USING SPLICE SLEEVES 

Tools Required 

J-38125 Terminal Repair Kit. See Special Tools and Equipment . 

Splicing Copper Wire Using Splice Sleeves 

Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use 
duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions 
below in order to splice copper wire using duraseal splice sleeves. 

Splicing Copper Wire Using Splice Sleeves 

1. Open the harness. 

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If the harness is taped, remove the tape.  

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To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.  

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If the harness has a black plastic conduit, pull out the desired wire.  

2. Cut the wire. 

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Cut as little wire off the harness as possible.  

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Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and 
connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 

IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the 

splice from moisture or provide a good electrical connection.

Splice Sleeve Color

Crimp Tool Nest Color

Wire Gauge AWG/(Metric)

Salmon 

12089189

Red

20,18 / (0.5, 0.8)

Blue 

12089190

Blue

16, 14 / (1.0, 2.0)

Yellow 

12089191

Yellow

12, 10 / (3.0, 5.0)

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 10: Proper Crimping Of Solderless Connector 
Courtesy of GENERAL MOTORS CORP. 

3. Select the proper size and type of wire. 

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The wire must be of equal or greater size than the original.  

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The wires insulation must have the same or higher temperature rating (4). 

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Use general purpose insulation for areas that are not subject to high temperatures.  

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Use a cross-linked polyethylene insulated wire for areas where high temperatures are 
expected. 

IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not 

replace cross-linked polyethylene with PVC. 
Cross-linked polyethylene wire is not fuel resistant. Do not use 
to replace wire where there is the possibility of fuel contact.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

4. Strip the insulation. 

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Select the correct size opening in the wire stripper or work down from the largest size.  

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Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).  

5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal 

Splice Table.  

6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at 

point 1 on the splice.  

7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper 

crimp tool nest.  

8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a 

stop in the middle of the barrel in order to prevent the wire from passing through the splice (3).  

9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The 

crimper handles will not open until the proper amount of pressure is applied to the splice sleeve.  

10. Shrink the insulation around the splice. 

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Using the heat torch apply heat to the crimped area of the barrel.  

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Gradually move the heat barrel to the open end of the tubing. 

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The tubing will shrink completely as the heat is moved along the insulation.  

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A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is 
achieved.  

SPLICING TWISTED OR SHIELDED CABLE 

Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this 
construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications 
where low level, sensitive signals must be carried. Follow the instructions below in order to repair the 
twisted/shielded cable. 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 11: Outer Wiring Jacket 
Courtesy of GENERAL MOTORS CORP. 

1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape.  

2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the 

splice is made. 

Fig. 12: Inspecting Wiring Connections 
Courtesy of GENERAL MOTORS CORP. 

3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. 

Staggering the splices by 65 mm (2.5 in) is recommended. 

IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2