D-436-36 – Raychem (TE) MiniSeal SolderSleeve® Wire Splice (26-20 AWG, Red)
Available now on the Airparts.aero Marketplace.
Overview
The D-436-36 from Raychem (a TE Connectivity brand) is a high-reliability, heat-shrinkable wire-to-wire splicing device, and is not a conventional crimp connector. It is an engineered solution that utilizes SolderSleeve® technology to create a soldered, strain-relieved, and fully environmentally sealed connection in a single, controlled application process. The red color-coded sealing rings indicate that this splice is designed for the 26-20 AWG (American Wire Gauge) range.
This component consists of a transparent, radiation-crosslinked polyvinylidene fluoride (PVDF) heat-shrinkable sleeve that contains a precisely engineered preform of solder and flux, along with two thermoplastic sealing rings. When heated, the sleeve shrinks to provide strain relief, the solder melts to form a superior electrical connection, and the sealing rings melt to create a waterproof and fluid-resistant barrier. This technology is the industry standard for creating certifiable, permanent wire splices that often meet or exceed the integrity of the original aircraft wiring harness.
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: D-436-36
Component Type: Heat-Shrinkable SolderSleeve® Wire Splice
OEM Manufacturer: Raychem / TE Connectivity
Wire Gauge Range: 26 AWG to 20 AWG
Color Code: Red
Sleeve Material: Radiation-crosslinked Polyvinylidene Fluoride (PVDF)
Solder Alloy: Per SAE-AS83519 (typically Sn63 Pb37 or RoHS compliant equivalent) with integrated flux.
Sealing Ring Material: Thermoplastic Copolymer
Maximum Operating Temperature: -65°C to +150°C
Governing Specification: SAE-AS83519/2
Aircraft Compatibility
The D-436-36 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, condensation, and fluids (e.g., landing gear bays, wings, engine pylons).
Used to create high-integrity connections for flight control, navigation, communication, and engine sensor circuits.
Why Choose D-436-36?
For a permanent wire splice, the D-436-36 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 D-436-36 SolderSleeve® operates on the principles of controlled material phase change and capillary action. The process is initiated by a precisely controlled heat source. First, the thermoplastic sealing rings undergo a phase change from solid to a viscous liquid, allowing them to flow and adhesively bond to the wire insulation. Simultaneously, the radiation-crosslinked PVDF sleeve, which has a shape memory, shrinks to its original smaller diameter, applying a consistent radial pressure to the components within. This pressure holds the stripped wire conductors in place as the pre-fluxed solder preform melts. The flux activates, cleaning the conductor surfaces, and the molten solder flows via capillary action throughout the wire strands, creating a uniform, low-resistance, and metallurgically sound intermetallic bond. Upon cooling, all components return to a solid state, resulting in a fully soldered, insulated, strain-relieved, and hermetically sealed joint.
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 D-436-36 at https://www.te.com/