D436-37 - Butt Splice Blue

D436-37 – Raychem (TE) SolderSleeve® Wire Splice (20-16 AWG, Blue)

Available now on the Airparts.aero Marketplace.

Overview

The D436-37 from Raychem (a TE Connectivity brand) is a high-reliability, heat-shrinkable wire-to-wire splicing device designed for 20 to 16 AWG wire, as indicated by its blue color code. This is not a crimp connector; it is an advanced, single-piece solution that utilizes SolderSleeve® technology to create a soldered, strain-relieved, and fully environmentally sealed connection. It is the aerospace industry standard for performing permanent, certifiable in-line wire splices in the most demanding environments.

The component's design integrates a transparent, heat-shrinkable polyvinylidene fluoride (PVDF) sleeve with an internal, pre-fluxed solder preform and two thermoplastic sealing rings. In a single, controlled heating step, this device simultaneously solders the conductors for a superior electrical bond, shrinks to provide robust mechanical strain relief, and melts the end-seals to create a waterproof barrier against fluids and moisture.

Key Features

• SolderSleeve® Technology: An integrated, pre-fluxed solder preform melts during heating to create a consistent, reliable, low-resistance soldered joint without the need for manual soldering.

• Environmentally Sealed Connection: Thermoplastic sealing rings at each end melt and flow during installation, creating a waterproof, immersion-resistant seal that protects the connection from moisture, corrosion, and hydraulic fluids.

• Transparent Inspection Window: The transparent PVDF outer sleeve allows for a complete visual inspection of the solder flow after installation, verifying the quality of the electrical connection.

• Integral Strain Relief: The tough, heat-shrunk sleeve provides excellent strain relief and mechanical protection for the splice, preventing wire fatigue from vibration.

• SAE-AS83519 Qualified: Manufactured and qualified to the rigorous SAE-AS83519/2 aerospace standard for "Shield Terminators and Wire-to-Wire Splicing," ensuring the highest level of performance and reliability.

• Single-Step Application: Replaces a multi-step process of crimping, soldering, and insulating with a single application using a calibrated heat source.

Technical Specifications

• Part Number: D436-37

• Component Type: Heat-Shrinkable SolderSleeve® Wire Splice

• OEM Manufacturer: Raychem / TE Connectivity

• Wire Gauge Range: 20 AWG to 16 AWG

• Color Code: Blue

• Sleeve Material: Radiation-crosslinked Polyvinylidene Fluoride (PVDF)

• Solder Alloy: Per SAE-AS83519 (typically Sn63 Pb37 or similar) with integrated flux.

• Sealing Ring Material: Thermoplastic Copolymer

• Maximum Operating Temperature: -65°C to +150°C

• Governing Specification: SAE-AS83519/2

Aircraft Compatibility

The D436-37 is a universal wiring system component used in the manufacturing, repair, and modification of electrical harnesses on virtually all modern certified aircraft, including those from:

• Textron Aviation (Cessna, Beechcraft, Hawker)

• Boeing

• Airbus

• Bombardier

• Embraer

• Gulfstream

• And all other major OEMs.

Note: This is a standard wiring component. Applicability is determined by the wire gauge and the requirements of the specific wiring repair or installation as detailed in the aircraft's maintenance and wiring manuals.

Applications

• Permanent, in-line splicing of electrical wires in airframe, powerplant, and avionics systems.

• Ideal for wiring repairs in areas exposed to moisture, fluids, and vibration (e.g., landing gear bays, wings, engine pylons).

• Used to create high-integrity connections for general power, lighting, flight control, navigation, and communication circuits.

Why Choose D436-37?

For a permanent wire splice, the D436-37 provides a level of reliability that a simple unsealed crimp cannot match. A standard crimp is susceptible to failure from corrosion caused by fluid ingress and metal fatigue from vibration. The SolderSleeve® creates a superior soldered connection that is then fully protected from the environment and mechanically supported by the tough outer sleeve. This eliminates the primary failure modes of lesser splices, ensuring the long-term integrity of the electrical connection, which is critical for the safety and reliability of modern avionics and fly-by-wire systems.

The robustness of the D436-37 splice is largely attributable to its outer sleeve, which is made from radiation-crosslinked Polyvinylidene Fluoride (PVDF). During manufacturing, this material is exposed to electron-beam radiation, which creates covalent bonds between the polymer chains. This crosslinking process transforms the thermoplastic into a thermoset material that will not re-melt when heated; instead, it possesses a shape memory. This allows it to shrink to a predetermined size, providing a strong compressive force on the components within. The resulting shrunken sleeve exhibits exceptional mechanical toughness, high tensile strength, and superior resistance to abrasion and cut-through. Furthermore, PVDF is chemically inert to a wide range of aerospace fluids, including jet fuel, hydraulic fluid (Skydrol), and de-icing fluids, ensuring the splice's integrity and insulating properties are maintained for the life of the airframe.

Note: This is a flight-critical electrical component. Installation must be performed by a certified A&P or avionics technician trained in aerospace wiring practices. Use of a calibrated, temperature-controlled heat gun with an appropriate reflector is mandatory; use of an open flame or uncontrolled heat source will damage the component and create an unairworthy connection. Proper wire stripping and insertion are critical for a reliable splice. The transparent body must be used to visually inspect the solder flow and verify a proper connection has been made.

Documentation

The military and aerospace standard governing this part is publicly available through standards organizations. Manufacturer's data sheets are available on the TE Connectivity website.

• Governing Specification (Reference): SAE-AS83519

• TE Connectivity Product Page (Reference): Search for D436-37 at https://www.te.com/