ARCHIVE Diesel truck fusible links

[NLXTACY]

I was asked months ago about building up fusible links for Toyota diesel trucks since they have been obsolete now for some time.

I’ve been trying to source components to make them but I can’t seem to find a Japanese wire source for two of the four fusible link wires. On top of that the battery ring terminal isn’t available by itself so I’ll need to use some Ancor or Amphenol wire terminals instead which is fine, just not OE.

If I cant find a Japanese wire replacement I’ll be stuck using an aftermarket fusible link wire which I’m not enthused about but desperate times... If anyone can steer me in the right direction that help get these over the finish line.

The battery ends will be 3/8” ring.

 

[NLXTACY]

My wiring notes

 

[Njck22]

I can't find anything on yellow fusible link wire except an old listing on Australian electronics site: FUSIBLE LINK WIRE YELLOW. Buy quality Auto and Marine Electric Parts and Accessories online, Sydney but it might not be yazaki but the wire gauge is close and I can't find anyone else who makes yellow fusbile link wire
Looks like the other colors are avaliable out of japan by many electronics suppliers, but it looks like you've got that sorted.


Thanks for posting this up. I've learned so much going on this google adventure.

 

[Njck22]

And for the purists you could always order TE-connectivity f-crimp m10 ring terminals. That's closer to OEM than the ancor, but to get a crimp like oem you need the tooling = very pricey. So Ancor is the way to go and very little compromised.

addendum: If you were talking about the interlocked ring terminals: Interlocking Ring Terminals

 

[NLXTACY]

And for the purists you could always order TE-connectivity f-crimp m10 ring terminals. That's closer to OEM than the ancor, but to get a crimp like oem you need the tooling = very pricey. So Ancor is the way to go and very little compromised.

addendum: If you were talking about the interlocked ring terminals: Interlocking Ring Terminals

AWESOME link on the ring terminals. Thanks!

EDIT: Bummer, the rings are too small but I ordered a bunch anyway.

 

[george_tlc]

FJ62 Fusible Link Fuse Equivalents?

I'm in the process of conducting open-heart surgery on my 3FE wiring harness and one of the things I want to change while I've got it opened up is to replace the 30+ y/o fusible links with something more modern. I've found a couple potential battery mounted power distribution boxes that might...

forum.ih8mud.com

You could use Red (50A) versus Yellow (60A) and more than likely be just fine. I doubt toyota pushes the envelope of the link rating to the near edge, since its main function is to protect the wiring. So 50A would protect more than 60A

Of course it's not totally factory so rabbits and other cute furry animals will be at risk.

If I had to deal with this, I'd replace with like rated MIDI fuses and resolve the issue once and for all, especially since you're making a new link harness anyway.

cheers,
george.

 

[NLXTACY]

FJ62 Fusible Link Fuse Equivalents?

I'm in the process of conducting open-heart surgery on my 3FE wiring harness and one of the things I want to change while I've got it opened up is to replace the 30+ y/o fusible links with something more modern. I've found a couple potential battery mounted power distribution boxes that might...

forum.ih8mud.com

You could use Red (50A) versus Yellow (60A) and more than likely be just fine. I doubt toyota pushes the envelope of the link rating to the near edge, since its main function is to protect the wiring. So 50A would protect more than 60A

Of course it's not totally factory so rabbits and other cute furry animals will be at risk.

If I had to deal with this, I'd replace with like rated MIDI fuses and resolve the issue once and for all, especially since you're making a new link harness anyway.

cheers,
george.

thats Plan B

 

[dan1554]

In doing a 24v to 12v starter conversion, I became much more familiar with the electrical systems, and found two more fusible links. One is a 0.5G link on the left battery:

The other is for the glow system resistor:

I have a spare HDJ81 harness on the way, so if you want me to send those out as well I'd be happy to. Best part is I won't be heckling you to give em back!

 

[NLXTACY]

Heck yeah!

 

[NLXTACY]

I finally got in the interlocking ring terminals from Corsa. I bought all the sizes they had. Not going to work because the ring size is getting smaller than even the OEM size. I may have to stay with the terminals I have