How do I repair my electric range dual-coil surface element wiring?

Question

My Kenmore (Whirlpool) model# 66595775890 mid-90s electric range dual coil surface element is not working. Upon inspection, discovered that the wire connecting the coil common terminal to the 1A (heater circuit) terminal of the temperature limiter was burned at the joint with its female crimp connector that goes into the (male) dual coil surface element common terminal.

This wire was also butt-spliced in the middle for some reason. (maybe because the crimp female terminals are of different size? ). I have looked everywhere for this exact part, but have not been able to find it stand-alone. Can you please suggest the best option to do this repair myself? Should I buy pre-crimped wires with different size female terminals to match those of the limiter and dual coil and butt-splice them together, or better to just get a single wire and the 2 different size female crimp connectors separately and crimp them myself? In both cases, what are the ratings of the wire/insulator/crimp connectors I should look for? (AWG, heat limit tolerance, insulator etc) ? Any link on where to buy them is appreciated!

I would also like to know about any tips for cleaning the common male terminal of the surface element. Just using a metal file, or is there any cleaning product to get rid of any corrosion/burned surface?

The terminals that I need to mount to:

The wire that has burned up and needs to be replaced:

Answer 1

It looks like this has already been repaired once before. Note how your bad wire looks like it's "standard" PVC insulated electrical wiring instead of being high-temp wiring with a woven cloth insulation like everything else in your pic? That's a clue and may indicate why this has failed this time.

Those look to be simple, standard spade and lug connections. If you are able to make a solder joint or use a crimper, you shouldn't have any issues making up a jumper wire yourself.

• You'll need to purchase some wire that's rated for high temperature stove/oven use.
• You'll need to purchase the female lug connector ends that are the correct size.
  • It's hard to judge from your picture, but you might need to purchase two different sizes.
  • Pull the female connector off of the lug shown on the right of the first pic. (The one left behind by the burnt wire.)
  • The 2nd pic shows a double connector at a right angle. I don't think you'd need to exactly duplicate this connection style. A standard straight-on connector should work, you'll just have to route the wiring slightly differently.

Your local big-box home improvement store might have the high temp wire you'd need to make this repair, so I suppose it's worth looking there. However, I'd guess you'd be more likely to have to go to either an electrical supplier or possibly an appliance repair place (do those still exist?) to find the proper wire. Call the closest electrical supplier and ask them if they have wiring appropriate for use inside a stove/oven. If yes, head on down and buy some. They'll probably also have a large supply of spade connectors and are likely to have the correct size. You may end up having to buy many more than you'd like, but you'll have them on hand for future use.

If they say no, ask them if they can recommend anyone who might have it. Most likely, they'll be more than willing to make a recommendation if it's something they don't stock and can't order in. Local places tend to want to be helpful.

Once you've got all your parts:

• Crimp one connector on
  • You could solder, but it may fail using home soldering techniques in the heat around the oven. Check your solder for its melting vs working temp range.
  • Crimp for a good mechanical connection then solder for a good electrical connection is probably even better.
• Slide that connector onto one spade end
• Make a nice run to the other connector to measure length.
  • You may have to reroute the wire to make a nice loop, especially if you use straight on connectors instead of the 90° connector shown.
• Crimp the other connector on.
• Push both female connectors onto their male counter parts.
• Get to cooking.

Answer 2

Take all the pieces of the wire to your nearest used appliance place. They likely will have an appropriate part kicking around or can splice a new one up for you. Then replacement is trivial.

As to cleaning the terminals, I love Scotch-Brite or similar scouring pads for doing it. You can also use steel wool or a copper pot scrubber.

Answer 3

You won't find bits of wire and crimp terminals in the replacement parts catalog. At the average electrical supply house you'll find terminals, but IMHO it's pretty unlikely you'll find high-temp wire like this. Maybe if it's a supply house that serves industrial customers, rather than supplying only "average" commercial and residential jobs.

Find somebody who is giving away a junk range (or buy a cheap used one found in the local classifieds). Drag it home, tear off the covers, and look inside until you find the right kind of terminal crimped to a length of good high-temperature wire. Cut out the length you need. Give away or throw away what's left of the junk range.

Clean the damaged terminal with a scouring pad ("scotch-brite" or similar) or steel wool. Make sure that when you slide the new terminal on it takes plenty of force to do -- this indicates a good snug fit. You can put a little bend in either or both of the terminals to make the fit a little tighter if necessary.

Splice the salvage wire segment to a good part of the original conductor in your range. A butt crimp terminal should do. Make this splice some distance (say 6+ inches) away from the heating coil if you can.