HDJ81 Fusible Links

[ToyotaMatt]

I can't tell if that wire is SAE J1128. I'd recommend the most durable wire rated for this which should be J1128 SXL.

16AWG = 1.29mm diameter (1.31mm2 area) which should be close enough.

do you know where to source it today in the LOWER 48 ?

 

[jellis]

SAE-J1128-SXL: 16-Gauge: Automotive Cross Link Wire | Waytek Wire

Automotive Cross-Link Wire is available in SAE Type GXL, TXL, and SXL. Available by the foot in whatever length you need. Order now!

www.waytekwire.com

Gotta buy 500 feet min, but it's not crazy expensive either.

 

[ToyotaMatt]

SAE-J1128-SXL: 16-Gauge: Automotive Cross Link Wire | Waytek Wire

Automotive Cross-Link Wire is available in SAE Type GXL, TXL, and SXL. Available by the foot in whatever length you need. Order now!

www.waytekwire.com

Gotta buy 500 feet min, but it's not crazy expensive either.

i don't see or understand clearly this is indeed fusible link wire , at a fundamental level ?

the term CROSS-LINK is vague

can anyone chime in here that can help determine if this is the last missing link to our needewd fusible links puzzle

THANKS !

here is these definition :

Automotive Cross Link Wire | Waytek Wire

Automotive Cross-Link Wire is available in SAE Type GXL, TXL, and SXL. Available by the foot in whatever length you need. Order now!

www.waytekwire.com

Automotive Cross Link Wire - TXL, GXL & SXL Style​

Waytek Wire’s cross-link automotive wire is constructed with chemically altered polyethylene insulation, making it more durable and resistant to heat than standard GPT automotive wire. Our auto wiring features a smooth surface finish and is resistant to moisture, grease, oil, gasoline, most acids and solvents.

This wire is typically used in high temperature areas, such as connecting wiring to circuit protection devices in engine compartments or automotive wiring connectors. Our cross-link wire comes in SXL, GXL, and TXL wire styles and meets SAE J1128 standards. It’s offered in standard wall to extra thin wall insulation for space and weight reduction, as well as multiple sizes, from 22 AWG to 8 AWG.

 

[ToyotaMatt]

this is the point i don't fully understand at all :


" such as connecting wiring to circuit protection devices in engine compartments "


the 1.25mm fusible links wire we seek IS the circuit protection in it self ?


thanks for any input here

-----------------------------------------------------------------------------------------------------------------------

- also :

UPDATE :

neither AU based Ebay seller will consider shipping to the USA , even a bulk purchase order like i suggested to them ?


i honestly feel very stuck here at the moment ?


and

stuck sucks !

 

[HillCountryTX]

@ToyotaMatt, perhaps the standard we are referencing (i.e. SAE J1128) is not necessarily applicable in this case. If you look up "fusible link wire" it seems that the SAE J156 standard is more applicable here as it specifically mentions the usage as a "fusible link" application, rather than a low voltage primary cable in the case of SAE J1128.

According to the SAE.org website:

SAE J1128 --> J1128_202012: Low Voltage Primary Cable - SAE International - https://www.sae.org/standards/content/j1128_202012/
SAE J156 --> J156_202207: Fusible Links - SAE International - https://www.sae.org/standards/content/j156_202207/

So if you go look for fusible link wire under the SAE J156 standard you get many choices that are right here in the US. I am not endorsing Wiring Depot by any means, but they offer the following fusible link wire in cuts and spools: Fusible Link Wire - Cuts and Spools - https://www.wiringdepot.com/store/p/703-Fusible-Link-Wire-Cuts-and-Spools.aspx

Granted these are primarily sold by AWG, so you would have to approximate the closest cross-sectional area (mm^2) to the AWG size.

Hope this helps!

 

[ToyotaMatt]

it does , thanks ...


i don't care if anyone endorses anybody who has what we need in the end of the day ...............



- the only thing that matters most to me really , is helping the HDJ81 community with there fusible links needs ....

- if you told me here in the beginning of my first post in this tech thread , the links wire itself would be the sticking point to Manifest ?

i would have said no way Jose ! ,

- the UNICORN female connector housings or maybe the male harness side ones too perhaps could be a deal breaker UNOBTAINABLE parts need related here ?


- i never cease to learn something new here on MUD each and every day for sure


- that being said , i just need to be certain this is the correct product that meets that and this need ?

i will contact them tomorrow by a live phone call and find out more

thanks for your input here on this topic

kindly ,
matt

 

[jellis]

Good catch @HillCountryTX!!! Looking at the scope of J156, it's a supplement to J1128--meaning it just adds requirements, so J156 = J1128 + More.

Based upon what I found from some MFG spec sheets, it looks like this is typically J1128 Type HTS + other crap....maybe insulation temp is higher so nothing flares when the wire degrades (contains the melt)?

Matt just call up wiring depot and say you need 1.25mm2 cross-section equivalent of that J156 Fusible Link wire. As I mentioned earlier it's probably closest to 16AWG but they will be able to look at their supplier spec sheets and give you exact dims to compare.

 

[ToyotaMatt]

ill be on the shop-hot line first thing about this topic ,


if i can match the YELLOW color coded link wire i will , the other will remain black if that is possible

thanks for both of your help here , @jellis @HillCountryTX !

i will update this thread here , when i have more solid news and it appears i will too .......


kindly matt

 

[ToyotaMatt]

UPDATE :

the correct OEM 1.25mm Fusible LINKS wire has been sourced from JAPAN , with included DHL H55F fast shipping ...

- i all-ready keep good stock of the correct 1.0mm , so we are good there ...

-

​

 

[ToyotaMatt]

the last part of this puzzle to be assembled is a live stand alone specimen of simply good close up TECH photos , if anyone has one removed please post a few photos ..

of a REAL 90982-08266


- this is needed now , because i have seen images that appear to have a 3rd un-known links / MM / millimeters Ga wire w / a ring terminal

attached to the end that services the wire harness and is / would be attached to my double sandwich style ring terminals shown in my mock up attached to the understood

2-wire links set up ?


- this possibility throws yet another possible curve ball into the equation


- or

- are now 2 different part #'s in the mix now maybe ?


thanks for any help on the last important detail


kindly matt

 

[ToyotaMatt]

i can clearly see a 3rd links wire in the mix here coming out of the same rubber boot up at the battery terminal ?


then in goes to the black junction box as a ring terminal for sure ...+


looks to be a 2nd 1.25mm ?

 

[Dusten]

I'll take a picture after work. Pretty sure both are 2 wire. From the ewd they're two.

I'm at work now so I'll grab it around 615

 

[ToyotaMatt]

Thanks Dustin ..

 

[ZCissner]

91 HDJ81

 

[Dusten]

91 HDJ81View attachment 3108825

He beat me to it. It was dark after work and in couldn't see under the hood.

 

[ToyotaMatt]

91 HDJ81View attachment 3108825

Thank You VERY VERY Much @ZCissner .......



exactly the TECH> image i need to confirm and verify the 90982-08266

 

[ToyotaMatt]

I'll take a picture after work. Pretty sure both are 2 wire. From the ewd they're two.

I'm at work now so I'll grab it around 615

91 HDJ81View attachment 3108825

well i found the TECH. here finally on the MYSTERY 3 link wires fusible links set up i was trying to confirm and verify above :

- this does NOT surprise me that there in another similar variation .......

- can anyone Identify the particular FUSABLE links application and part # ?


- its very very similar but indeed uniquely different for sure ....

 

[ToyotaMatt]

- the HDJ81 1.25mm TEq has finally landed

 

[ToyotaMatt]

​

 

[IanB]

So when ordering fusible links from you, do you need the date of manufacture to confirm what the customer would need, or what?