GM Astro/Safari 1985-1996 Repair Guide

Fusible Links


In addition to fuses, the wiring harness incorporates fusible links (in the battery feed circuits) to protect the wiring. Fusible links are 4 in. (102mm) sections of copper wire, 4 gauges smaller than the circuit(s) they are protecting, designed to melt under electrical overload. There are 4 different gauge sizes used. The fusible links are color coded so that they may be installed in their original positions.


See Figure 1

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Fig. Fig. 1: New fusible links are spliced and soldered to the wire

Here are some common fusible links and their locations. Refer to the wiring diagrams for specific fusible link information.

Fusible link A - Rust/silver, to ECM, located at starter solenoid.
Fusible link B - Gray/silver, to air conditioning blower, located at battery connection block.
Fusible link C - Black/silver, to fuel pump circuit, located at battery connection block.
Fusible link D - Black/silver, to ignition switch, located at battery connection block.
Fusible link E - Rust/silver, to alternator, located at starter solenoid.
Fusible link F - Rust/silver, to alternator (2.5L), located at starter solenoid.

Some replacement fusible links may be of a crimp on type style. This procedure is for splice and solder type links.

  1. Disconnect the negative battery cable from the battery.
  3. Locate the cause of the problem and repair before replacing the link.
  5. Locate the burned out link.
  7. Strip away the melted insulation and cut the burned link ends from the wire.
  9. Strip the wire back 1 / 2 in. (12.7mm) to allow soldering of the new link.
  11. Using a new fusible link 4 gauges smaller than the protected circuit and approximately 10 in. (254mm) long, solder it into the circuit.

Whenever splicing a new wire, always bond the splice with rosin core solder, then cover with electrical tape. Using acid core solder may cause corrosion.

  1. Tape and seal all splices with silicone to weatherproof repairs.
  3. After taping the wire, tape the electrical harness leaving an exposed 5 in. (127mm) loop of wire.
  5. Reconnect the battery.