Fuse Link and Butt Connector Service
SPECIAL SERVICE TOOL(S) REQUIREDDescription Tool Number
Wire Fitting Crimping Tool T67S-17018-A.
IDENTIFICATION
WARNING: ALWAYS DISCONNECT BATTERY GROUND CABLE PRIOR TO SERVICING ANY FUSE LINK.
CAUTION:
- Do not fabricate a fuse link from ordinary wire because the insulation may not be flame-proof.
- Before replacing a fuse link, be sure to find and correct the electrical problem that caused the link to blow.
If it becomes necessary to replace a fuse link in a wiring assembly, make sure the replacement fuse link is a duplicate of one removed with respect to gauge length and insulation. Original and Ford replacement fuse links have insulation that is flame proof.
NOTE: If the damaged fuse link is between two splices (weld points in a harness), cut out damaged portion as close to splices as possible.
If a circuit protected by a fuse link becomes inoperative, inspect for a blown fuse link. If the fuse link wire insulation is burned or opened, cut the feed as close as possible behind the splice in the harness. If the damaged fuse link is between two splices (weld points in the harness), cut out the damaged portion as close as possible to the weld points.
NOTE: Some fuse links have an eyelet terminal for an 8 mm (5/16 inch) stud on one end.
A new waterproof butt splice connector has been released that should be used on all service to wiring located in the engine compartment.
The duraseal heat shrinkable nylon splice provides a long-lasting splice that can withstand water, salt, condensation, corrosion and heat, all of which cause problems for conventional unsealed splices.
The inner wall of the splice connector is lined with a special adhesive that melts as the splice is heated and flows under pressure from the tubing, filling voids and sealing the splice.
The duraseal splice can be easily installed using a standard preinsulated crimp tool and a heat gun. They are also color-coded for easy identification of gauge sizes, yet are transparent for visual inspection of the finished splice. Refer to the illustration for installation instructions.
Wiring Assembly - Fuse Link (With Eyelet Terminal And One End Stripped):
Wiring Assembly - Fuse Link (With Insulation Stripped Both Ends):
When an eyelet terminal is not required, use one of the fuse links with insulation stripped from both ends.
1. To service a fuse link in a multi4eed or single circuit, proceed as follows:
a. Using a Rotunda 73 Digital Multimeter 105-R0051 or equivalent, determine which circuit is damaged, its location and cause of blown fuse link. If damaged fuse link is one of three fed by common No. 10- or 12-gauge feed wire, determine specific affected circuit.
Disconnect the battery ground cable.
b. Cut damaged fuse link from wiring harness and discard it. If fuse link is one of three circuits fed by single feed wire, cut it out of harness at each splice end and discard.
c. Identify and procure proper fuse link and butt connectors for attaching fuse link to harness.
CAUTION: DO NOT MISTAKE A RESISTOR WIRE FOR A FUSE LINK. The resistor wire is generally longer and has print stating: "Resistor-do not cut or splice."
d. Strip wires 7.6 mm (5/16 inch) and insert into proper size wire connector. Using Wire Fitting Crimping Tool T67S-17018-A, crimp and heat splice insulation until tubing shrinks and adhesive flows from each end of connector.
NOTE: When attaching a No. 16, 16 or 20-gauge fuse link to a heavy gauge wire, always double the stripped wire end of the fuse link before inserting and crimping it into the wire connector for positive wire retention.
e. To replace any fuse link on a single circuit in a harness, cut out damaged portion. Strip approximately 12.7 mm (1/2 inch) of insulation from two wire ends and attach correct size fuse link to each wire end with proper gauge wire connectors. Crimp and heat splice insulation until tubing shrinks and adhesive flows from each end of connector.
2. To service any fuse link which has an eyelet terminal on one end such as the charging circuit, proceed as follows:
a. Cut off open fuse link behind weld. Strip approximately 12.7 mm (1/2 inch) of insulation from cut end and attach appropriate new eyelet fuse link to cut stripped wire with an appropriate size connector.
b. Crimp and heat splice insulation until tubing shrinks and adhesive flows from each end of connector.