Fusible Link: Service and Repair

Purpose

Fusible links protect vehicle electrical systems from damage due to excessive current.

^ The most common cause of excessive current is a short to ground caused by a component or wiring failure.

Fusible links are color coded to indicate wire gauge and size.

Fig. 9 Fusible Link Chart:

CAUTION: Replace blown fusible links with correct gauge, hypalon insulated, fusible type wire ONLY.

^ Use of standard wire may result in severe damage to the electrical system or an electrical fire.

NOTE: Refer to the fusible link chart and the wiring diagrams for proper color and gauge identification.

Replacement

Splicing Wires:

CAUTION: If a fusible link has blown, find the cause before attempting to replace the link.

NOTE: If a faulty fusible link is suspected, it is important to carefully check the link for continuity over its entire length. In some instances the link may look fine and actually be blown.

1. Disconnect battery negative cable.

2. Cut out the blown portion of the fusible link.

3. Strip 1 inch of insulation from each end of the existing fusible link.

4. Place a piece of heat shrink tubing long enough to cover and seal the entire repair area over one side of the fusible link.

5. Cut a replacement piece of fusible link approximately two inches longer than the piece removed.

6. Remove one inch of insulation from each end of the replacement fusible link.

7. Spread the stripped ends of the wires apart (example 1).

8. Push the stripped ends of the wires together until the cut ends almost touch the insulation of the other wire (example 2).

9. Twist the wires together (example 3).

10. Solder the wires together using rosin core type solder only. Never use acid core type solder for soldering electrical/electronic connections.

11. Center the heat shrink tubing over the joint. Heat the joint with a heat gun until the tubing is tightly sealed and sealant is coming out of both ends of the tubing.