Traditional neon signs typically last a very long time. If a sign suddenly stops working after being shipped, moved, or bumped, the problem is often simply a cracked neon tube. If you don't see a crack but the sign flashes and immediately goes out when turned on, there may be a very small crack that is difficult to see.
Fortunately, on most neon signs, an individual tube can be easily replaced without replacing the entire sign.
What You'll Need
- Small wire cutters or nail clippers
- A couple of small cable ties
- Replacement neon tube
Always unplug the neon sign before replacing a tube.
Step 1: Remove the Broken Tube
Thin metal wires may be wrapped around the neon tube and the plastic supports. These are only used to secure the tube during shipping and are not electrical wires.
Use small wire cutters or nail clippers to snip them off. They do not need to be replaced.
Carefully pop the neon tube out of the plastic supports one at a time.
Step 2: Disconnect the Tube
At each end of the neon tube is a black rubber electrode cap. Carefully twist and slide the cap back to expose the wire connection.
Untwist the wire from the neon tube from the wire coming from inside the sign.
Don't let the wire from inside the sign slip back through the hole. An easy way to prevent this is to temporarily attach a small cable tie to it.
Repeat this at the other end and remove the old tube.
Step 3: Connect the Replacement Tube
Remove the temporary cable tie and securely twist the wire from the new neon tube to the wire coming from inside the sign. Make sure the wires have a good, tight connection.
Slide the black rubber electrode cap back over the connection and repeat at the other end of the tube.
Step 4: Secure the New Tube
Carefully press the new neon tube into the plastic supports one at a time.
The thin metal shipping wires you removed earlier do not need to be reinstalled. The plastic supports will hold the tube in place.
Step 5: Plug It In and Test It
Check that the tube is seated properly, both wire connections are secure, and the black electrode caps completely cover the connections.
Plug the sign back in and turn it on. That's it — your neon sign should be back up and running.
