WahooSteeler Posted September 26, 2020 Share Posted September 26, 2020 Need some edumacation on fusible links. I had one do it's job and need to replace it. First, the one that burned was one "side" of two different wires, different gauge, that are connected to the same eyelet which has a rubber connector of some sort at that point. The individual wires have another rubber connector where they connect to the harness. I know the fusible link wire is supposed to be 4 gauges higher than the harness wire, and the factory parts manual lists 14ga and 18ga fusible links. The 18ga is what burned up on mine. Replacement fusible link wire is available in many forms. Some is simply wire with an eyelet attached, some have a rubber piece at the base of the eyelet, and some have a rubber piece "in line" of the wire. Reading closer on some product descriptions, on the "in line" versions at least, it seems that rubber piece is there to hold a blade fuse? The ones with the rubber piece at the base of the eyelet, the description does not specify it is an actual fuse holder. So my questions are: which type is a proper replacement to splice in? What is the function of the rubber connector on the OE harness? Link to comment Share on other sites More sharing options...
WahooSteeler Posted September 26, 2020 Author Share Posted September 26, 2020 Link to comment Share on other sites More sharing options...
eaglescout526 Posted September 26, 2020 Share Posted September 26, 2020 Sucks no one has given you an answer. If you have those part numbers handy I’ll run them real quick and I can snag you some OEM ones for ya if that will ease you. Link to comment Share on other sites More sharing options...
WahooSteeler Posted September 26, 2020 Author Share Posted September 26, 2020 15 minutes ago, eaglescout526 said: Sucks no one has given you an answer. If you have those part numbers handy I’ll run them real quick and I can snag you some OEM ones for ya if that will ease you. No worries, headed out now to pick some up from Napa, need to get it fixed today. I think I understand what I need, just wanted to be 100% sure. I'll ask the guy at Napa, they usually know more than the typical box store cashier. Still might see about you getting me some OEM ones as backup later. Thanks! Link to comment Share on other sites More sharing options...
eaglescout526 Posted September 26, 2020 Share Posted September 26, 2020 No problem. I know theres a few OEM ones left, never had a reason to snag them up...yet. Link to comment Share on other sites More sharing options...
jdog Posted September 26, 2020 Share Posted September 26, 2020 Any of them would work, I would use one of the eyelet ones as it's one less thing to crimp. The rubber is just a covering where it was spliced Link to comment Share on other sites More sharing options...
WahooSteeler Posted September 26, 2020 Author Share Posted September 26, 2020 1 hour ago, jdog said: Any of them would work, I would use one of the eyelet ones as it's one less thing to crimp. The rubber is just a covering where it was spliced Thanks Jdog! Link to comment Share on other sites More sharing options...
jdog Posted September 26, 2020 Share Posted September 26, 2020 yep, which one did you get? Link to comment Share on other sites More sharing options...
WahooSteeler Posted September 27, 2020 Author Share Posted September 27, 2020 8 hours ago, jdog said: yep, which one did you get? I got the one with the eyelet and rubber cover from Napa, part # 784690. I went ahead and got a 14ga one to have on hand also, part # 784692. However, there is a reason the factory setup has multiple links joined at 1 eyelet. The mounting post on the relay for all the items to get power at startup is maxed out with having another individual eyelet added to the stack. If I have to replace another one in the future, I would just get the fusible link wire with no connectors and then splice it back to stock configuration by sharing another eyelet. Fyi, I split open the big rubber connector where the harness and fusible link are spliced together. As you said, that is all the rubber piece is, a very secure and weatherproof solder covering. Pic of the parts from Napa and the burned up link wire that was replaced. Link to comment Share on other sites More sharing options...
jdog Posted September 27, 2020 Share Posted September 27, 2020 Did you figure out why it blew? Link to comment Share on other sites More sharing options...
WahooSteeler Posted September 27, 2020 Author Share Posted September 27, 2020 13 minutes ago, jdog said: Did you figure out why it blew? Yes. Somehow, my o2 sensor wires pulled out of the sensor body and I assume caused a short. Ohm confirmed for me the link replaced is the one for the o2 heater and the fuel pump. I have another thread going because I thought my fuel pump had died. My son was driving it and it just died on him on a back road. It was close enough to home I was able to "tow" it with a strap myself and when I first crawled under the truck to see if I could hear the fuel pump prime, I noticed the o2 wires hanging down. I have a theory how it may have happened after a recent trip to the shop, but no way to prove it. Anyhoo, glad it's up and running and actually learned a lot in the past week troubleshooting many things and ultimately finding the burned up link. Link to comment Share on other sites More sharing options...
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