A fusible link is a protective device used in an electrical circuit. When the current increases beyond a certain amperage, the fusible metal of the wire link melts, thus breaking the electrical circuit and preventing further damage to other components and wiring. Whenever a fusible link is melted because of a short circuit, correct the cause before installing a new one.
The X-Body cars have three fusible links. Two of them are located at the front center of the engine, at the starter solenoid. One protects the lighting circuit and the other protects the starting and charging circuit. The third fusible link is in the wiring harness at the right-hand side of the car, at the cowl; it protects the engine cooling fan.
- Disconnect the negative battery cable, followed by the positive cable.
- Locate the burned out link.
- If both ends of the link are ring terminal connectors which are easily accessed:
- Measure the installed length necessary for the new link.
- Unbolt and remove the link and connector pieces.
- Obtain a suitable length of link, then strip the insulation off the harness wire back 1 / 2 in. (12.7mm) to allow soldering of the new connectors.
- Position the new connector around the new link and crimp it securely. Then, solder the connection, using rosin core solder and sufficient heat to guarantee a good connection. Repeat for the remaining connection.
Whenever splicing a new wire, always bond the splice with rosin core solder, then cover with electrical tape. Use of acid core solder may cause corrosion.
- If the ends of the connector are not easily accessed, repair the length in the vehicle:
- Strip away the melted insulation and cut the burned link ends from the wire.
- Strip the wire back 1 / 2 in. (12.7mm) to allow soldering of the new link.
- Using a new fusible link of appropriate gauge and length, solder it into the circuit.
- Tape all exposed wiring with electrical tape and seal with silicone or use a heat shrink tube, if available, to weatherproof the repair.
- If removed from the vehicle, install the link and secure the connectors.
- Reconnect the positive, followed by the negative battery cables.