Fusible Link Hacked - 97 80 Series

[hogan646]

Hi All,
The PO removed the fusible link but kept the junction box. I want to have the link replaced but I don’t know what the gray clip on the fusible link connects to. Does anyone have a wiring diagram for that set up? I have the part numbers for the link and the box but don’t know if there is another wire with the connector that I need. Thanks.

 

[ZackR]

A photo of the current setup would be helpful.

 

[hogan646]

Current set up.

 

[jonheld]

There are 3 fusible links bonded together at the battery terminal. 2 go to the junction box and the 3rd goes to the grey connector.

 

[hogan646]

There are 3 fusible links bonded together at the battery terminal. 2 go to the junction box and the 3rd goes to the grey connector.

Thanks Jonheld - do you happen to know what the gray connector clips to?

 

[jonheld]

Thanks Jonheld - do you happen to know what the gray connector clips to?

Not sure what you mean by "clips to". The grey fusible link connector (AM2) should have a mating half that lives by the battery.

 

[hogan646]

Not sure what you mean by "clips to". The grey fusible link connector (AM2) should have a mating half that lives by the battery.

Yes, that mating half is what I am missing? Is that a specific part numbe. Thanks for the help.

 

[jonheld]

Yes, that mating half is what I am missing? Is that a specific part numbe. Thanks for the help.

I suspect it's not "missing" or the engine wouldn't run. It has to be getting +12 from somewhere.

 

[hogan646]

Agreed, I think it was just hardwired. Bypassing the fusible link completely. I want to install the fusible link but don’t know what it needs to on the other half

 

[hogan646]

Agreed, I think it was just hardwired. Bypassing the fusible link completely. I want to install the fusible link but don’t know what it needs to on the other half

The junction box wires are connected directly to the positive terminal.

 

[Bambusiero]

Not sure what the grey connector powers in the system, but recent experience shows that a broken wire in that path kills the engine.

 

[hogan646]

I think I figured it out thanks to mud. I look to be missing the two below parts along with the actual fusible link.

• Connector housing is part# 90980-10982
• Repair wire is part# 82998-12470

Does that make sense? Thanks.

 

[MoJ]

Black and blue to the junction box. Pink to the plug. Pics stolen from Wit’sEnd so buy the parts there.

 

[hogan646]

MoJ - thanks

 

[nodaksn3]

Gonna steal this good thread: I'm having trouble with my 1995 80 starter. I note from Jon's diagram that the S1 wire must be the big gray honker that goes to the main terminal of the starter; so the S2 must be the smaller wires to the black male/female connector on the starter?? Am I correct? I just replaced the starter w/a rebuilt, and (naturally) broke the black connector. Got a new one coming from the dealer. Maybe the AM1 relay if bad? I've had a slight delay from when I turn the key to start and the starter kicks in. Could the relay be the issue? The truck has 334,000 or so miles on it and I've had it for 16 years. I confess to meticulous maintenance! Thanks for any input, Ned

 

[Box Rocket]

A previous owner of my truck modified the fusible link also and it's set up probably the same way as the OP. The gray plug isn't used on mine either. I'll try to get a picture of mine so you can see how it's all connected.

 

[Dave 2000]

I removed them altogether and fitted a new Blue Seas fuse box on the inner wing. Less crap around the terminals, way more reliable and replaceable in the field. I have come across a few over the last few years, they rot from the inside out, they can look OK but will fail when you least expect it. With the youngest LC 80 out there now over 20 years old, it is worth thinking about.

regards

Dave

 

[hogan646]

I removed them altogether and fitted a new Blue Seas fuse box on the inner wing. Less crap around the terminals, way more reliable and replaceable in the field. I have come across a few over the last few years, they rot from the inside out, they can look OK but will fail when you least expect it. With the youngest LC 80 out there now over 20 years old, it is worth thinking about.

regards

Dave

Thanks for the information.

Update - I had a NJ cruiser shop (Kenny Dean’s) sort out the wiring issue. Anyone looking for a NJ shop, they are great.

 

[Box Rocket]

Here's mine. Grey plug unused. The factory wire that would connect there looks to be wired directly to the battery. Has been this way the entire time I've owned the truck. But I have cleaned it up a bit.
Untitled by Adam Tolman, on Flickr

Untitled by Adam Tolman, on Flickr

 

[BillyGoatMTB]

I removed them altogether and fitted a new Blue Seas fuse box on the inner wing. Less crap around the terminals, way more reliable and replaceable in the field. I have come across a few over the last few years, they rot from the inside out, they can look OK but will fail when you least expect it. With the youngest LC 80 out there now over 20 years old, it is worth thinking about.

regards

Dave

Do you have a photo and part number for the Blues Seas fuse box you mentioned? Still working well for you?