Abstract: A method of remanufacturing an injector involves an original lead extending from an overmold block. A milling cutter is used to mill a cavity into the overmold block to provide access to the original lead. The milling cutter splits the original lead into a remainder portion and a discard portion. A replacement lead is inserted into the overmold block to overlap with the remainder portion, and the overlapping leads are soldered to each other. The exposed overlap area is encapsulated with filling material. The original lead is preferably cut such that a tip of the remainder portion is angled, pointed, or otherwise shaped to increase the surface area that is exposed at the tip. The increased exposed surface area increases the area over which the replacement lead and the remainder portion make contact with each other when overlapping. Greater contact between the soldered leads strengthens their connection.