Wire Repair - not mc

[Peder_y2k]

How to repair these wires to save this perfectly good 12v fuel pump? The insulation on the wires has become stiff resulting in a strained transition into the pump body. As you can see in the images, the wire is beginning to break off. How to fix?

-Pete, in Tacoma WA USA

[KeithR]

Some solder and liquid electrical tape ? Silicone?

[Flyinfool]

Since that looks like a potted assembly and that the conductors are damaged right where they go into the potting, your only hope is to very carefully remove some of the plastic around the wires to expose the wire, you can then solder new wires onto the remains of the old wire. If you can get this much to work, then fill in the holes you dug around the wires with some epoxy to cover the joint and then after the epoxy is cured build up some RTV around the wires to act as a strain relief.

 

If this does not work then your only choice is to buy a new pump.

[jakester]

Just a thought, If the pump is weak and pulls too many amps, this will / can cause heat build up at the pump and the wire insulation will get brittle and crack...Be your own judge. Plain old silicone sealer can seal the gaps in the insulation. If the silicone is exposed to the fuel it will break down.

Good Luck,

Bill