BJ42 fusible link replacements?

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

BackRoads

BackRoads

10 Year
Joined
Nov 9, 2014
Threads
6
Messages
23
Location
Laurentians, Quebec
Hi All! I have a 1982 Canadian BJ42 which I'm really enjoying now that I found myself some rear doors and got them mounted ...
New Rear Doors.webp


Thanks to a really helpful guy in Toronto for that!

My problem, however, is ... of course ... headlights. Turns out a PO hated the center tap so much that he took it out! Gone! Fusible link, wire, yep ... just gone.

So I'm trying to source some information here. I know this has appeared in threads already, but I can't seem to find aftermarket sources of these links, Toyota tells me the parts is discontinued, surprise. What I actually want to do is find replacements for all fusible links in the truck:
Fusible Links bj42 wiring diagram.webp


Now the 3 off the 24V battery (highside) pole are present in a state of decay :
24 V fusible links all of them BJ.webp


Now I don't have an EDIC motor - I shut it off with a throttle cable attached to the injection pump. I believe one of these is only for that.

And the missing center tap on the -'ve pole of the highside battery (it's the thing you can't see!):
Missing Center Tap.webp


I don't even know what gauge of wire I should be replacing the original with ... it goes to pin 8 on the dimmer relay and the "neutral" pin of the right headlamp.

So ... long story short, I can't cruise at night until I get some replacement parts! Any information on:

1. wire gauge
2. replacement headlight fusible link
3. replacement 24V fusible links
4. exact location of dimmer relay on a Canadian 82

Thanks in advance for any insight. And thanks to a fellow Mudd member who was kind enough to send me the wiring schematic for a 1981 BJ42 ... I was pretty lost without it.

These are awesome vehicles; I teach high school, and the biggest problem I am having is getting out of the parking lot at the end of the day. Teenagers out here don't often know what they are ... but they know they're special!
PB095954.webp


Thanks!
 
You can buy 25ft oF gauge wire from ebay for $10-15. One seller says as a general rule ,you use fuse wire 4 sizes smaller than the circuit wire so for 12 gauge circuit wire ,you use 16 gauge fuse wire. But you need to check that. Tried the parts stores in your area? All the shops in Australia sell it by the spool or by the metre.
Its all color coded , I think I used the pale green wire on my FJ73 but the oem wire was yellow(what was left of it was fairly burnt).
 
Thanks to both of you. I had read that fusible link is always 4 gauges smaller than the circuit it is in. Makes sense. Would the light circuit in my truck be 12 gauge? Is that standard automotive gauge wire? I'll hit the part stores and ask for generic fusible link wire.

Appreciate it!
 
Problem mostly solved! Thanks Rudi, not only for sending me that wiring diagram, but for the above link. I actually stumbled on it last night, and it explained it all loud and clear. I'm checking part stores tomorrow for fusible link wire, or making my own following your instructions. Awesome thread, that one.

And thanks ozcruiser for the pictures. I don't have a full manual.

Very supportive cruiser owners out there in the world ...

Scott
 
Primo, this may have helped me solve the problem im having with my cruiser, would really like to get the thing running so I can go hunting next weekend! I wonder where I can find fusible link wire in Wellington
 
MBlakeBJ42 said:
Primo, this may have helped me solve the problem im having with my cruiser, would really like to get the thing running so I can go hunting next weekend! I wonder where I can find fusible link wire in Wellington
Click to expand...

I doubt you will.

I'm in Wellington and had to get a helpful mud-member in the USA to buy it and send me some..

But rather than put someone through that hassle again, I think if I were to need some more I'd just use ordinary automotive wire and slide the original fabric sleeves over the top.

AFAIK, the only difference between fusible link wire and ordinary wire is the insulation (with fusible link wire using a material that is less combustible).


:beer:

PS. If your really keen on REAL fusible link wire, you could use an outfit like this to enable you to buy from someone who ships only within the USA:
http://www.borderlinx.com/NZ/en/?utm_expid=2275136-3.OOicaA5pR8qcyu5BFRgvwQ.0

(I've been meaning to give this a try but haven't done so yet.)
 
lostmarbles said:
I doubt you will.

I'm in Wellington and had to get a helpful mud-member in the USA to buy it and send me some..

But rather than put someone through that hassle again, I think if I were to need some more I'd just use ordinary automotive wire and slide the original fabric sleeves over the top.

AFAIK, the only difference between fusible link wire and ordinary wire is the insulation (with fusible link wire using a material that is less combustible).


:beer:

PS. If your really keen on REAL fusible link wire, you could use an outfit like this to enable you to buy from someone who ships only within the USA:
Buy in the USA, ship to New Zealand with Borderlinx

(I've been meaning to give this a try but haven't done so yet.)
Click to expand...

Hard case, I was about to email you and esquire where abouts in NZ you were located before you replied to this. So I can just replace with higher gauge, regular wire you think? And insulate it. Or maybe wire a fuse in place instead. Where abouts in Wellington are you? You might be a hugely valuable source of information for me!
 
I'm not a fan of swapping to fuses personally.

Yes. I believe ordinary wire will work just as well so long as you take steps to mitigate fire risk.

I've sent you a pm

:beer:
 
You must log in or register to reply here.

Share this page

Back
Top Bottom