GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Fusible Links

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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. There are four different gauge sizes commonly used and they are usually color coded so that they may be easily installed in their original positions.

REPLACEMENT



See Figure 1

  1. Disconnect the negative battery cable, followed by the positive cable.
  2.  
  3. Locate the burned out link.
  4.  
  5. If both ends of the link are ring terminal connectors which are easily accessed:
    1. Measure the installed length necessary for the new link.
    2.  
    3. Unbolt and remove the link and connector pieces.
    4.  
    5. 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.
    6.  
    7. 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.
    8.  

  6.  

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



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Fig. Fig. 1: Fusible links may be repaired by soldering a new link into the wire

  1. If the ends of the connector are not easily access, repair the length in the vehicle:
    1. Strip away the melted insulation and cut the burned link ends from the wire.
    2.  
    3. Strip the wire back 1 / 2 in. (12.7mm) to allow soldering of the new link.
    4.  
    5. Using a new fusible link of appropriate gauge and length, solder it into the circuit.
    6.  

  2.  
  3. Tape all exposed wiring with electrical tape and seal with silicone or use a heat shrink tube, if available, to weatherproof the repair.
  4.  
  5. If removed from the vehicle, install the link and secure the connectors.
  6.  
  7. Reconnect the positive, followed by the negative battery cables.
  8.  

 
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