Originally Posted by stevebfl

The copper core wires never "wear" out. They often get destroyed by heat or chemicals. The TVRS carbon core wire used in US style wiring is responsible for the common conception that replacing wires is a maintenance item. The european style of wires never need wholesale replacement; only the necessary repairs. Occasionally I will replace all the ends where I have had more than one fail. They are easily seen on a scope when bad.

The part that goes bad is the resistor end that goes on the plug. These are easily replaced and the Beru ends are easily available. The job is cheap and easy.

My trick for replacing the ends is designed to save the wire. The wire has a metal "male" screw made to it (which is also available separately to repair those done in haste) which screws into the "female" connection inside the plug wire end.

I slit the rubber boot on the end and peel it back. this uncovers a white ceramic insulator. I wrap it with a rag and squeeze it with strong pliers/visegrips till it fractures. Pick away the pieces (watch they are sharp) and you will see the metal connection made to the wire. This can now be grabbed and the end turned from it. If you turn the wire from outside the boot the wire will probably break from the metal end instead of unscrewing properly.

Since the end is being thrown away a little destruction can save having the wire end ruined. By doing this instead of wholesale wire replacement one saves money, restores the original ends, maintains the factory coverings and solves the electrical problems.