Fusible link help urgent 🙏 (5 Viewers)

[in2twins]

The smaller black wire from the fusible link block melts when I connect power during a jump start. In the picture it is the wire that was soldered together. What are my next steps and parts required?
Also what does the soldered wire go to that may be compromised?

In the second image is a red wire(I think it was originally black) without this wire car will not run. Any idea what it’s for?

 

[tmxmotorsports]

No pictures

 

[Curtice]

Not sure since your picture didn't appear to work, but here are a couple threads that might help. I already had these open as I am dealing with a similar problem.

Black looks like it is to the alt

Fusible Link Question

Still need to do this! Almost forgot, thanks. To many repairs not enough time!

forum.ih8mud.com

SOLD - Boise, ID - Fj62 Fusible Link with pigtail

Clearing out spares for more 60 series stuff… Fj62 Fusible Link - complete, beautiful condition with pigtails off chassis harness if needed. $140 shipped.

forum.ih8mud.com

Edit - I didn't even notice I was in the 80 forum :| .

 

[in2twins]

No pictures

 

[in2twins]

 

[in2twins]

Not sure since your picture didn't appear to work, but here are a couple threads that might help. I already had these open as I am dealing with a similar problem.

Black looks like it is to the alt

Fusible Link Question

Still need to do this! Almost forgot, thanks. To many repairs not enough time!

forum.ih8mud.com

SOLD - Boise, ID - Fj62 Fusible Link with pigtail

Clearing out spares for more 60 series stuff… Fj62 Fusible Link - complete, beautiful condition with pigtails off chassis harness if needed. $140 shipped.

forum.ih8mud.com

Pictures re-posted

 

[in2twins]

No pictures

Pictures re-posted

 

[jonheld]

Honestly, I have to wonder what people were thinking when doing stuff like that. It's about $30 in parts to do it correctly.
You need to return to a stock configuration. Please purchase a new set of fusible links (90982-08264), a new junction box (82670-60040).
The cut white/red stripe wire should connect to fusible link AM2 and feeds the ignition circuit.
Please download the correct Toyota manuals (FSM and EWD) for your vehicle from the resources section.

 

[Brindleboxer]

As @jonheld said, you are best to go back to stock and work from there. IMO the current setup is just asking for a fire as it bypasses Toyota designed safety measures. Here is a picture of the part that should be there.

I always keep an extra in my glove box as well since they are prone to go out at inconvenient times.

 

[Inyo80]

I concur. Just inspected mine and was shocked to see how close to disaster I was. All three wires were more than 40% severed. Its an easy replacement and a cheap part so no need to skimp.

View attachment 3545084

 

[Inyo80]

Image issue...

 

[jonheld]

The smaller black wire from the fusible link block melts when I connect power during a jump start. In the picture it is the wire that was soldered together. What are my next steps and parts required?
Also what does the soldered wire go to that may be compromised?

In the second image is a red wire(I think it was originally black) without this wire car will not run. Any idea what it’s for?

Another thing to note is that fusible links are not "just wire". They are specifically designed to be inline, flameproof fuses. As noted on the drawing I posted earlier, there are 3 in the bundle that connect to the positive battery terminal.
PINK=30 amps
BLACK=80 amps
BLUE=100 amps

 

[surfpig]

I thought mine was bad when I finally replaced it! 26 years is a pretty good run.

 

[Marvelicious]

Honestly, I have to wonder what people were thinking when doing stuff like that.

I assume that's what industrial maintenance people refer to as a "temporary" repair. Experience has shown that the acceptable lifespan for a temporary repair is, "as long as it will work like that". I always wonder if some of these people have tarps covering their roofs at home.

 

[jwbc84]

Something I've been wondering is where are these two fusible links located? The three close to the battery are easy to find. Are these two wrapped into the loom? That doesn't make sense.

 

[ToyotaMatt]

The smaller black wire from the fusible link block melts when I connect power during a jump start. In the picture it is the wire that was soldered together. What are my next steps and parts required?
Also what does the soldered wire go to that may be compromised?

In the second image is a red wire(I think it was originally black) without this wire car will not run. Any idea what it’s for?

Not sure since your picture didn't appear to work, but here are a couple threads that might help. I already had these open as I am dealing with a similar problem.

Black looks like it is to the alt

Fusible Link Question

Still need to do this! Almost forgot, thanks. To many repairs not enough time!

forum.ih8mud.com

SOLD - Boise, ID - Fj62 Fusible Link with pigtail

Clearing out spares for more 60 series stuff… Fj62 Fusible Link - complete, beautiful condition with pigtails off chassis harness if needed. $140 shipped.

forum.ih8mud.com

Edit - I didn't even notice I was in the 80 forum :| .

I thought mine was bad when I finally replaced it! 26 years is a pretty good run. not a ad

,

FJ80 FZJ80 1991-1997 HARNESS SIDE Fusible LINK Links Repair Connector KIT FORM Problem Solver Solution 100% OEM TOYOTA & ANCHOR MARINE Part # 90982-00080 - VintageTEqParts.com

- - NEW 100% TOYOTA OEM GENUINE PARTS & ANCHOR Marine Wire - Hand Crafted & Made 100% IN-HOUSE By...

vintageteqparts.com

.

 

[ppc]

Something I've been wondering is where are these two fusible links located? The three close to the battery are easy to find. Are these two wrapped into the loom? That doesn't make sense.

Based on the wiring diagram the text looks to be calling out an automatic breaker and not a fusible link. Should be located in the engine compartment fuse box.

 

[jwbc84]

Had to dig out the EWD. I never read close enough and assumed the three wiggly lines were fusible links. But the number of lines is correlated to amperage.

 

[jonheld]

Something I've been wondering is where are these two fusible links located? The three close to the battery are easy to find. Are these two wrapped into the loom? That doesn't make sense.

Those 2 are not fusible links. They are fuses. All of this information is in the EWD.
If you look on the first page of section H (POWER SOURCE) you will see that both 50 amp AM1 and 60 amp ABS fuses have a number 1 indicating relay block #2 as noted on the bottom of the page. If you turn to page 18 as noted, it shows you the relay block.
There is also an entire section (B HOW TO USE THIS MANUAL).

 

[TomH]

Something I've been wondering is where are these two fusible links located? The three close to the battery are easy to find. Are these two wrapped into the loom? That doesn't make sense.

View attachment 3545690