Fusible links

[phatairman]

Any ideas on removing the nut on the larger post in the junction box? Seems the last mechanic tightened it with an impact gun.

Can't get torque to hold the box and then to loosen the nut. One or the other.

 

[Dave 2000]

Mine fell apart but I was replacing with fuses anyway, tried soaking over night with a release agent?


regards

Dave

 

[phatairman]

I was wondering if PB Blaster would be a bad thing on those electrical connectors.

 

[NLXTACY]

Any ideas on removing the nut on the larger post in the junction box? Seems the last mechanic tightened it with an impact gun.

Can't get torque to hold the box and then to loosen the nut. One or the other.

Just use a large pair of piers around the junction block. Then replace block.

 

[Tools R Us]

I was wondering if PB Blaster would be a bad thing on those electrical connectors.

Why would it be?

 

[nuclearlemon]

The junction box is fairly cheap. I just bought a new one. Does not come with nuts, so get a new one of those if necessary too

 

[Flipped Bezel]

Just use a large pair of piers around the junction block. Then replace block.

Finally figured this out after breaking the snap in plastic cover off of my junction box.

After not getting anywhere for a few minutes struggling to break the nut with a 3/8" ratchet and socket, I used a pair of channel lock pliers and put the socket on a short breaker bar and it broke with minimal effort.

Oh well...off to AWE to get replacements and a spare. Thanks @NLXTACY

 

[JOHN OF LONDON]

I replaced mine with 'mega' fuses. Mine being a diesel the wiring is a little different, the fusible link ratings are a little difficult to track down, I found one and had to guess the other. I went by what the circuit was supplying and also the gauge of the wire and the maximum amps I could get the various circuits to pull. I did go one size lower than my estimation, and the mega fuse did not blow but did get warm, heater fan on full, headlights, HRW etc. I went up a size and the fuse body stayed cool, been in there quite awhile now with no issues.

regards

Dave

Hi Dave,
Can you recall what sizes of Mega fuses you used; and which fusible link each replaced?
Cheers, John

 

[jvazquez53]

One of my friends installed one of these and he says it works great. Im thinking going that route.

CIRCUIT BREAKER 285 SERIES BLUE SEA COOPER BUSSMANN 7189 150 AMP DC BOAT MARINE | eBay

 

[JOHN OF LONDON]

Mmmmm. Not sure that I understand. Are you suggesting this as a replacement for all three fusible links or as another circuit breaker between the battery and the OEM fusible links?
John

 

[jvazquez53]

Mmmmm. Not sure that I understand. Are you suggesting this as a replacement for all three fusible links or as another circuit breaker between the battery and the OEM fusible links?
John

I think so, He did some rewiring, I would have to see pictures of what he exactly did. I he provide me pictures, I'll post them here.

 

[george_tlc]

One of my friends installed one of these and he says it works great. Im thinking going that route.

CIRCUIT BREAKER 285 SERIES BLUE SEA COOPER BUSSMANN 7189 150 AMP DC BOAT MARINE | eBay

Bad idea, for the exact reason I already posted in your alternator thread.

A circuit breaker is not a fusible link replacement and certainly not in our 80s that have 3 fusible links of different ratings to protect 3 different gauge wiring harness runs. Don't meddle with things that are not your expertise unless you want to replace a harness or vehicle (if it bursts into flames).

I could use a nail to replace the fusible link too - no need for the expense of a circuit breaker. It'll work just fine too.... until it is called on to melt. How can you prove that the nail doesn't work great?

cheers,
george.

 

[Flipped Bezel]

Not sure what the "mega fuses" cost...but you could buy 3 OEM fusible links from @NLXTACY for the cost of the circuit breaker linked above.

I had to use a short piece of similar gauge jumper wire to get me back on the road for a few days until my replacement arrived...but I would never attempt to re-engineer this system that has been designed to sacrifice itself in order to protect the wiring harnesses.

These components are way too cheap and work too well for me to try and improve on it by "upgrading" to a questionable alternative solution.

 

[Dave 2000]

Hi Dave,
Can you recall what sizes of Mega fuses you used; and which fusible link each replaced?
Cheers, John

I replaced all the fusible links (3) individually, I found two of the correct ratings in the FSM, the third for the glow plugs was a simple maths exercise. There was enough slack in the cables to fit the fuse box on the inner wing, nice neat and tidy.

Regards

Dave

 

[Cruisin4Miles]

Going to be ordering the set from witts end right now.... might as well. New battery, new alternator, geez why not.

 

[BillyGoatMTB]

Evening Fellow Muds

Replacing the fusible links in my 97 80 series. Thank you for the suggestion to order a spare, cheap insurance was good advise.

Does anyone know the male plastic connector part number on the vehicle side of the fusible link connector (grey round single pin connector)? The PO was kind enough to cut the male end and bypass the f usable link on the plastic connector wire.

Also, anyone know where that wire goes? If it was bypassed my concern is hooking the link back up may burn it up, i may need to repair an unknown problem. I am sure the PO bypassed it for a reason and if able i would like to replace the entire circuit.

Thanks Mud!

 

[BillyGoatMTB]

Evening Fellow Muds

Replacing the fusible links in my 97 80 series. Thank you for the suggestion to order a spare, cheap insurance was good advise.

Does anyone know the male plastic connector part number on the vehicle side of the fusible link connector (grey round single pin connector)? The PO was kind enough to cut the male end and bypass the f usable link on the plastic connector wire.

Also, anyone know where that wire goes? If it was bypassed my concern is hooking the link back up may burn it up, i may need to repair an unknown problem. I am sure the PO bypassed it for a reason and if able i would like to replace the entire circuit.

Thanks Mud!

I think I found it doing a second search on Mud. I'll leave this here for the next guy.

Fusible Link Hacked - 97 80 Series

forum.ih8mud.com

 

[sogncab]

Old thread, but while trying to resolve an unrelated issue I came across this thread.

I've routinely get a code for a coolant temp sensor, occasionally a code for an intake temp sensor, and a code for the O² sensor after the cat. The O² sensor, will likely require tricking the computer. I've got headers and aftermarket exhaust.

Also have an issue with some rough running shortly after starting with a cold engine.

Replaced the fusible link and the junction box this evening.

I ohm'd out the one that was in previously. Two legs showed 1 ohm, the other zero'd out.

I don't freaking believe this, but it runs better, and shifts way better. Usually coming to a complete stop and applying ~50% throttle or betterwould trigger the coolant sensor code. I only have about 15 miles on it, but no codes. The fact it is more peppy and is shifting better blows my mind. What a stupid fix, and I'll be happy as hell if it cures some things.

Fusible link and the junction box are still available from Toyota.