HDJ81 Fusible Links (1 Viewer)

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Why not use the fusible link (82627-60020) from an HZJ7series? The plug in connector may be different but that is easily remedied.
 
Easy to make your own for $10 and you would have spare wire left over.
 
Why not use the fusible link (82627-60020) from an HZJ7series? The plug in connector may be different but that is easily remedied.
This is the HZJ7* connector

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I used 90982-08236 for my 1Hz, only about $7-10 from Partsouq or Megazip, easy to modify your wiring to get the connector to mate up. What I did is here (post 7,060):

Also, @coldtaco may still have PN 82627-60020 available (newer 1Hz fusible link) That would work as well, but again you may run into connector issues. That can be remedied fairly easily if it doesn't mate to your wiring.

 
I used 90982-08236 for my 1Hz, only about $7-10 from Partsouq or Megazip, easy to modify your wiring to get the connector to mate up. What I did is here (post 7,060):

Also, @coldtaco may still have PN 82627-60020 available (newer 1Hz fusible link) That would work as well, but again you may run into connector issues. That can be remedied fairly easily if it doesn't mate to your wiring.


What i'm looking for is for an HDJ81 (1hdft engine )
 
Further research unraveled that the new diesel fusible link part # (1-HDT) is 90982-08267, rather than 90982-08266. Does this check out? 90982-08267 are available online still. or maybe it's just another in the long laundry list of fusible links...
 
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Further research unraveled that the new diesel fusible link part # (1-HDT) is 90982-08267, rather than 90982-08266. Does this check out? 90982-08267 are available online still.


you need one tonight ?
 
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you need a 90982-08267 tonight ?

Hey Matt. I've been looking for a spare (or two). Was hoping someone else could corroborate that 90982-08267 was what the 1-HDT was, I'll inspect my rig in the morning to see if I can compare what I've got with that image.
 
Hey Matt. I've been looking for a spare (or two). Was hoping someone else could corroborate that 90982-08267 was what the 1-HDT was, I'll inspect my rig in the morning to see if I can compare what I've got with that image.


let me give you a better image here

also , if the 08267 is NOT correct , i keep on-hand ALL gauges fusible links wire and 99% of the needed connector plugs too , i kustom make fusable links as part of well ....


what i do for a living , here at the skunk works Laboratory


have you ever seen my ANYTHING JDM / Diesel TECH fusible links master thread i started a while back ?


i have documented all the variations i have come across and been asked to reproduce exactly same in kind , all i need is good pics of a verified original specimine photos

to work from , ...


and let me tell you what my friend , there seams to be NO dam limit to all the different one off one modle year only part #'s used here and there around the world !!


i venture to say there are well over 100+ unique and different vintage Toyota land cruiser links at the very least .........

and is NOT a over thought at all ....
 
I like the challenge and like helping folks get back on the road by the FSM ..
 
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Any confirmation on the Fusible Link 90982-08267 replacing the 90982-08266 @cgmud ?

I am in a similar situation with wanting some spare fusible links to have on hand, as mine are all original (31+ years old) and it is probably only a matter of time before at least one of them gives up due to age.

Based on my research, using both ToyoDIY and Partsouq.com using my VIN #, my 1991 HDJ81 (1HD-T) has at least four fusible links:

90982-08206 ---> Glow Resistor; E/G Wire Glow
90982-08227 ---> 50 Amp
90982-08265 ---> 110, 0.5, Starter
90982-08266 ---> Main, Glow, Head, AM1

Of those four, I would probably want a spare of at least the 90982-08266 at the minimum. Spares for all would be ideal.
 
Any confirmation on the Fusible Link 90982-08267 replacing the 90982-08266 @cgmud ?

I am in a similar situation with wanting some spare fusible links to have on hand, as mine are all original (31+ years old) and it is probably only a matter of time before at least one of them gives up due to age.

Based on my research, using both ToyoDIY and Partsouq.com using my VIN #, my 1991 HDJ81 (1HD-T) has at least four fusible links:

90982-08206 ---> Glow Resistor; E/G Wire Glow
90982-08227 ---> 50 Amp
90982-08265 ---> 110, 0.5, Starter
90982-08266 ---> Main, Glow, Head, AM1

Of those four, I would probably want a spare of at least the 90982-08266 at the minimum. Spares for all would be ideal.

I think replacing was the wrong term, as continued reading (and posts here) shows me that there was just simply a lot of different kinds, different plug types, etc. In another thread, someone figured out what 1.25B and 2.0L mean, and the gauge wire associated. I think fusible links use special wiring too, so you can't just use normal wire. This leads me to believe that the best route may be purchasing the still available FZJ80 fusible links and swapping plug types to make it HDJ81 compatible.

Sounded like Joey was going down this path, but probably found a roadblock somewhere.

I recently posted in the 80 series FB group and many suggested fuses. I've been hoping to retain fusible links for now, but it sounds like that's a popular option for the diesels over in Australia. Others mentioned a new part number or them somehow being available over there, but I haven't gotten definite information on that. If I do, I'll post here.

FB Post Permalink: 80 Series Owners - Private Group
 
Thanks @cgmud , as always.

To share what I've run into: I've done a bunch of research into making my own HDJ81 fusible links and, like you point out, there are several aspects you have to get right to ensure you have a properly protected circuit. To begin with the fusible link wire is special type of automotive wire with non-flammable insulation to accommodate the designed failure method (i.e. melting when the current is too high for too long so that the circuit is broken). Also, the fusible link wire's cross sectional area (mm^2) and the length are absolutely critical to maintaining the proper protection for the rest of the wiring. It is definitely possible do DIY your own fusible links, but it involves a lot of knowledge to make sure you have it right. Not to mention the connectors that you have to source, or adapt, to be able to connect to the rest of the circuit.

There are other options like you point out...using fuses (MIDI fuses/MAXI fuses) alongside some Blue Sea fuse boxes and proper wiring. @Dave 2000 has given me a lot of good pointers about how he did his setup and what he used.

Like you, I will share any information I obtain, or provide what the solution I come up with in terms of dealing with fusible links on my HDJ81. I know this is something that every HDJ81 owner will have to deal with at some point in the vehicle's service life :) I have not decided whether I will make my own fusible links, transition to a MIDI/MAXI fuse setup, or something else.
 
Have you ever looked into re-creating 90982-08266?


yes im looking into it right now as we speak for another member ,


by chance , do you or anyone have a good photo of the 90982-08266 ?

i know there is a plastic plug connector 2 pin on the end that services the main wire harness , but the profile is pretty un-common indeed
 
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yes im looking into it right now as we speak for another member ,


by chance , do you or anyone have a good photo of the 90982-08266 ?

i know there is a plastic plug connector 2 pin on the end that services the main wire harness , but the profile is pretty un-common indeed


I am 99% I need one too. I'll probably have to fab a replacement out of fusible wires as I don't have time to wait. But here's an image.

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