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
Here are some common fusible links and their locations. Refer to the wiring diagrams for specific fusible link information.
Some replacement fusible links may be of a crimp on type style. This procedure is for splice and solder type links.
- Disconnect the negative battery cable from the battery.
- Locate the cause of the problem and repair before replacing the link.
- Locate the burned out link.
- 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 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.
- Tape and seal all splices with silicone to weatherproof repairs.
- After taping the wire, tape the electrical harness leaving an exposed 5 in. (127mm) loop of wire.
- Reconnect the battery.