GM Chevy Mid-Size Cars 1964-1988 Repair Guide

Fusible Links

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A fusible link is a protective device used in an electrical circuit and acts very much like a standard fuse. The major difference lies in that fusible links are larger and capable of conducting higher amperages than most fuses. When the current increases beyond the rated amperage for a given link, the fusible metal of the wire link will melt, thus breaking the electrical circuit and preventing further damage to any other components or wiring. Whenever a fusible link is melted because of a short circuit, correct the cause before installing a new one. Most models have four fusible links.

REPLACING FUSIBLE LINKS



See Figures 1 and 2

  1. Disconnect the negative battery cable, followed by the positive cables. If the link is connected to the junction block or starter solenoid, disconnect it there as well.
  2.  
  3. Cut the wiring harness right behind the link connector(s) and remove.
  4.  
  5. Strip the insulation off the harness wire back 1 / 2 in (12.7mm).
  6.  
  7. Position the clip around the new link and wiring harness or new connector 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.  
  9. Tape all exposed wiring with electrical tape. Where necessary, connect the link to the junction block or started solenoid. Reconnect the positive, followed by the negative battery cables.
  10.  



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



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Fig. Fig. 2: Fusible link repair

 
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