Help recreating BJ60 fusible link

[Eurasiaoverland]

I've got together most of the bits I need to make my own fusible link assembly for my BJ60. I still have the original but would like to retire it and replace it with my own, and have an additional spare to swap straight in if necessary. The fusible link is no longer available and does not have the same wire rating as the still-available 1HZ fusible links.

The one piece I am struggling with is the large double-clamped, double wire ring terminal (8 mm hole) which goes onto the battery terminal. My idea is to use two standard large-gauge 8 mm ring terminals, but I can see it will be a struggle to clamp the thick insulation and get a good clamp on the copper filaments.

Does anyone have a good solution for this non-standard terminal?

Thanks
EO

 

[red66toy]

I've got together most of the bits I need to make my own fusible link assembly for my BJ60. I still have the original but would like to retire it and replace it with my own, and have an additional spare to swap straight in if necessary. The fusible link is no longer available and does not have the same wire rating as the still-available 1HZ fusible links.

View attachment 3297963

The one piece I am struggling with is the large double-clamped, double wire ring terminal (8 mm hole) which goes onto the battery terminal. My idea is to use two standard large-gauge 8 mm ring terminals, but I can see it will be a struggle to clamp the thick insulation and get a good clamp on the copper filaments.

View attachment 3297969

Does anyone have a good solution for this non-standard terminal?

Thanks
EO

Look into “ interlocking ring terminals” . That should solve your issue.

 

[CruiserTrash]

Look into “ interlocking ring terminals” . That should solve your issue.

Wow, never knew those existed. Neat.

 

[Eurasiaoverland]

Look into “ interlocking ring terminals” . That should solve your issue.

Sumitomo make left and right-handed stacking terminals (they are found in my wiring loom where it earths on either side of the dashboard), but they are M6. I had seen them before and thought about trying to use them but had not realised that they were two terminals clipped together and figured they were a specially made piece not available separately. But following your reply I searched and found that a shop in the UK can supply them.

I'm going to order a few and see if I can make it work, they will need opening very slightly with a file or drill to slip over the M8 stud on the battery positive terminal.

Thanks very much for the suggestion!

EO

 

[red66toy]

Excellent! Glad you found a source on that side of the ocean. Sumitomo to boot . It’s definitely a bit odd that M6 seems to be the main size available but hopefully they can be made to work.

 

[Gerhard O]

I've got together most of the bits I need to make my own fusible link assembly for my BJ60. I still have the original but would like to retire it and replace it with my own, and have an additional spare to swap straight in if necessary. The fusible link is no longer available and does not have the same wire rating as the still-available 1HZ fusible links.

View attachment 3297963

The one piece I am struggling with is the large double-clamped, double wire ring terminal (8 mm hole) which goes onto the battery terminal. My idea is to use two standard large-gauge 8 mm ring terminals, but I can see it will be a struggle to clamp the thick insulation and get a good clamp on the copper filaments.

View attachment 3297969

Does anyone have a good solution for this non-standard terminal?

Thanks
EO

Hi EO, can you please let me know where you ordered the Housing,connector from? (part number 90980-10123) Many thanks.

 

[Eurasiaoverland]

Hi EO, can you please let me know where you ordered the Housing,connector from? (part number 90980-10123) Many thanks.

I got mine from Amayama.com, but any competent dealer who orders Toyota parts should be able to get them.

 

[ToyotaMatt]

Hi EO, can you please let me know where you ordered the Housing,connector from? (part number 90980-10123) Many thanks.

I got mine from Amayama.com, but any competent dealer who orders Toyota parts should be able to get them.

i have these complete BJ60 Fusible Links assy. kits pre-assembled , includes a NEW OEM Propper Land Cruiser positive battery terminal and OUM Japan Spec. B+ Protection cover boot , using the correct OEM 8mm Ring Terminals as well


.

 

[Gerhard O]

I got mine from Amayama.com, but any competent dealer who orders Toyota parts should be able to get them.

Thank you. Appreciated.

 

[Gerhard O]

i have these complete BJ60 Fusible Links assy. kits pre-assembled , includes a NEW OEM Propper Land Cruiser positive battery terminal and OUM Japan Spec. B+ Protection cover boot , using the correct OEM 8mm Ring Terminals as well


.


View attachment 3366825

Matt, Can you supply me with only these plugs? I will do the wiring.

 

[Gerhard O]

I got mine from Amayama.com, but any competent dealer who orders Toyota parts should be able to get them.

Do you perhaps know what the part number for the other side of the connector is? as per the photo below.

 

[Eurasiaoverland]

Do you perhaps know what the part number for the other side of the connector is? as per the photo below.

View attachment 3367591

The male equivalent to -10123 is 90980–10122. This part is showing as being out of stock, which may mean it comes back, but may mean it's effectively discontinued.

 

[Gerhard O]

The male equivalent to -10123 is 90980–10122. This part is showing as being out of stock, which may mean it comes back, but may mean it's effectively discontinued.

Thanks a lot for letting me know. Much appreciated.

 

[Eurasiaoverland]

Thanks a lot for letting me know. Much appreciated.

Most welcome.

Your profile states you are in South Africa - I'd be interested to know what years (if any) you got the BJ60? Specifically, did you get the 1988/89 modely year BJ60 with four square headlights and the 3Bii (flat-top, blue block 3B)? I have one here in SE Asia and wonder if it was ever sold anywhere else.

Hopefully ToyotaMatt can sort you out with the connectors you need to rebuild your fusible link. If he doesn't have it then you're probably down to looking at second hand options - an old Toyota wiring harness from a scrap yard can give you lots of usefull connectors and wiring.

EO

 

[Gerhard O]

Most welcome.

Your profile states you are in South Africa - I'd be interested to know what years (if any) you got the BJ60? Specifically, did you get the 1988/89 modely year BJ60 with four square headlights and the 3Bii (flat-top, blue block 3B)? I have one here in SE Asia and wonder if it was ever sold anywhere else.

Hopefully ToyotaMatt can sort you out with the connectors you need to rebuild your fusible link. If he doesn't have it then you're probably down to looking at second hand options - an old Toyota wiring harness from a scrap yard can give you lots of usefull connectors and wiring.

EO

We got the FJ60 before 1988, I think in 1986. The FJ62 (with the 4 square headlights) was available here from 1988. We only had the 3F here as far as I know.

Im waiting for ToyotaMatt to respond, thanks.

 

[ToyotaMatt]

We got the FJ60 before 1988, I think in 1986. The FJ62 (with the 4 square headlights) was available here from 1988. We only had the 3F here as far as I know.

Im waiting for ToyotaMatt to respond, thanks.

Most welcome.

Your profile states you are in South Africa - I'd be interested to know what years (if any) you got the BJ60? Specifically, did you get the 1988/89 modely year BJ60 with four square headlights and the 3Bii (flat-top, blue block 3B)? I have one here in SE Asia and wonder if it was ever sold anywhere else.

Hopefully ToyotaMatt can sort you out with the connectors you need to rebuild your fusible link. If he doesn't have it then you're probably down to looking at second hand options - an old Toyota wiring harness from a scrap yard can give you lots of usefull connectors and wiring.

EO

hi ,

i DO have both the green square-ish connectors above and the 2-pin round ones also ....


PM me please


thanks

 

[ToyotaMatt]

We got the FJ60 before 1988, I think in 1986. The FJ62 (with the 4 square headlights) was available here from 1988. We only had the 3F here as far as I know.

Im waiting for ToyotaMatt to respond, thanks.

Most welcome.

Your profile states you are in South Africa - I'd be interested to know what years (if any) you got the BJ60? Specifically, did you get the 1988/89 modely year BJ60 with four square headlights and the 3Bii (flat-top, blue block 3B)? I have one here in SE Asia and wonder if it was ever sold anywhere else.

Hopefully ToyotaMatt can sort you out with the connectors you need to rebuild your fusible link. If he doesn't have it then you're probably down to looking at second hand options - an old Toyota wiring harness from a scrap yard can give you lots of usefull connectors and wiring.

EO

the Green Monsters ...

 

[Gerhard O]

thanks ToyotaMatt. I PM'd you.

 

[Gerhard O]

This is my FJ62. There is no other reset project (totally OEM) like this one in the world that I know of. Enjoy....

 

[Eurasiaoverland]

So finally today, I got quality 5 mm ring terminals (not the paper-thin Chinese type) and crimped them on to complete my original BJ60 fusible links. Very happy (visually at least) with the results.

I'm thinking of making another set with the 80A link replaced by a 100A link which might be needed for the 12V intake heater which is going onto my 15B-T.

Thanks for the input.

EO