KZJ78 Fusible links (1 Viewer)

[94KZJ78W]

Hi trying to solve a no-start issue on KZJ78…only have hazards and horn power, nothing else…can someone please post a picture of the “fusible links” running from battery? Can you replace the fuse on these?

Thank you

Edit: New fusible links fixed the problem. Special shout out to @ToyotaMatt for hooking up the new links!!!

 

[Felde]

I don't have a pic at hand, but can guide you:
Fusible Links are pieces of cable that are made from a special material intended to melt when Amp overloaded.
In original configuration, those are directly attached to the battery Positive-terminal clamp with ring terminals. Two or three cables (ca 20cm long), going from the clamp into a screw connector, which attaches the fusible links to the actual harness. That connector has a plastic housing.
As they are literally cables and actually form the first section of the harness, you might not have recognized them as such. Just look at your Positive-terminal and assess the cables you have there.

To change those fusible links, you can undo them from the battery clamp and that screw connector, to swap them out.
Many fusible links are discontinued, though. There is a guy on mud here who builds spares. Some also replace those with a small aftermarket fusebox.
Good Luck Ralf

 

[AirheadNut]

This is from an LJ78 rather than a KZJ78, but the fusible links should be similar. Often there isn't a good visual indication that the fusible links are blown, your best option is to test for voltage at the harness end with a multimeter.

 

[94KZJ78W]

I don't have a pic at hand, but can guide you:
Fusible Links are pieces of cable that are made from a special material intended to melt when Amp overloaded.
In original configuration, those are directly attached to the battery Positive-terminal clamp with ring terminals. Two or three cables (ca 20cm long), going from the clamp into a screw connector, which attaches the fusible links to the actual harness. That connector has a plastic housing.
As they are literally cables and actually form the first section of the harness, you might not have recognized them as such. Just look at your Positive-terminal and assess the cables you have there.

To change those fusible links, you can undo them from the battery clamp and that screw connector, to swap them out.
Many fusible links are discontinued, though. There is a guy on mud here who builds spares. Some also replace those with a small aftermarket fusebox.
Good Luck Ralf

Ralf - thank you so much for the guidance…I think I found the links and I think mine are 2-cable links, I attached pic for confirmation…I circled what I believe are the fusible links and the red arrow with the question mark is a separate 2-cables with a gray cylindrical connector link that leads into the same harness as the fusible links. Do you know what those might be?

 

[Felde]

Hi
Yes, that's the fusible links; all three of them. No idea why one has that round connector; its factory standard.
To check whether any link is blown, check for current on the harness side connectors with a voltmeter.
Good Luck Ralf

 

[ToyotaMatt]

Ralf - thank you so much for the guidance…I think I found the links and I think mine are 2-cable links, I attached pic for confirmation…I circled what I believe are the fusible links and the red arrow with the question mark is a separate 2-cables with a gray cylindrical connector link that leads into the same harness as the fusible links. Do you know what those might be?

View attachment 3870606

Hi
Yes, that's the fusible links; all three of them. No idea why one has that round connector; its factory standard.
To check whether any link is blown, check for current on the harness side connectors with a voltmeter.
Good Luck Ralf

- i was huntering into this topic last night pretty deep and i did come op with 2 different part #'s for a KZJ78

- this is the later of the 2 part numbers based the Round Connector you have there


- Toyota does NOT give any sort of Links Spec.s for any of the 78 series , which is VERY ODD too ?


- so , .........


- all we need to do now is correctly COLOR CODE ID each of the 4 fusible links wires , and where each color code goes from the main ring terminal on your Battery

- this is Eazy Peezy ........


- get some simple mineral spirts / paint thinner ......NOT Brake Klean ..!

- wipe each fusible wire after you pull down the FIRE PROOF cloth loom , the wires under it / them will be much more colorful and happy , wipe the area with the paint thinner on a cloth a bit .,..... PRESTO bright Colors once again

- i do have all the correct OEM Japan Spec. electrical service parts on-hand to Hand Assemble this particular Fusible Links set up correctly , by the FSM ...

i have not yet run across this exact one , so i have no Jigs or Nots or photos to refer to ..........yet


but that all will change by this evening hopefully , and the KZJ78 90982- will lived once again .........

- oh , recent update : ALL fusible Links i personally reproduce and hand assemble now will come with the Harness Side Male Connector Housing , plenty of extra Terminals and any / all OEM Updated Stainless Steel Special Locking Flange Nuts too ..........

.
thanks
Matt

.

 

[ToyotaMatt]

This is from an LJ78 rather than a KZJ78, but the fusible links should be similar. Often there isn't a good visual indication that the fusible links are blown, your best option is to test for voltage at the harness end with a multimeter.
View attachment 3868400

.

View attachment 3868401

.



same exact my above applies to you and your LJ78 Fusible Links .....


i do have all the correct OEM japan spec. service parts , but no treasure map to tell me what color coded,.. fusible Link wire goes where in your Early Style

GLOW STICK GREEN ROBOT Connectors set up ....

.



.

 

[TreadingLight]

This doesn't sound like a fusible link problem. I don't have a kzj78 manual in front of me, but generally speaking, one link will be headlights, one link will be the glow system, and the third will go to everything else in the fusebox.

If your horn and hazards work, I'd expect you to also have other general functions - heater, wipers, starter solenoid, etc.

Stranger things have happened though.

I would pick up one or two spares from ToyotaMatt regardless, as you never know when they will become unavailable.

Is your battery good?

 

[94KZJ78W]

Hi
Yes, that's the fusible links; all three of them. No idea why one has that round connector; its factory standard.
To check whether any link is blown, check for current on the harness side connectors with a voltmeter.
Good Luck Ralf

 

[94KZJ78W]

Hi
Yes, that's the fusible links; all three of them. No idea why one has that round connector; its factory standard.
To check whether any link is blown, check for current on the harness side connectors with a voltmeter.
Good Luck Ralf

Ok so I shot for voltage and one of the 3 links wasn’t getting voltage, so I started to remove the links and found out that link was broken (did its job hopefully). Anyway, I google image searched the links and found an OEM replacement albeit for a different model cruiser…going to replace and see what happens. See pics below…

 

[Redline70]

Ok so I shot for voltage and one of the 3 links wasn’t getting voltage, so I started to remove the links and found out that link was broken (did its job hopefully). Anyway, I google image searched the links and found an OEM replacement albeit for a different model cruiser…going to replace and see what happens. See pics below…

View attachment 3875345

View attachment 3875346

View attachment 3875348

View attachment 3875349

This is @ToyotaMatt

 

[ToyotaMatt]

Ok so I shot for voltage and one of the 3 links wasn’t getting voltage, so I started to remove the links and found out that link was broken (did its job hopefully). Anyway, I google image searched the links and found an OEM replacement albeit for a different model cruiser…going to replace and see what happens. See pics below…

View attachment 3875345

View attachment 3875346

View attachment 3875348

View attachment 3875349

This is @ToyotaMatt

hi ,

- my 90982-08187 i hand assemble using all oem japan spec. parts , is NOT also for your KZJ78 .......

- i did do a bit of digging deep into this topic , as it relates to this specific thread , and the LJ78 & KCJ78 Fusible Links assy. both shown above by different fellow members and there particular trucks have both unique part #'s as you can see the primary connector housings are very very different ....

- this being said as best i can determine your above needed KCJ78 Fusible Links assy. part # is 82627-60030 ........ ( should be )

- this is a disc. / nla part # ......

- there is no links wires spec's on the EPC microfiche oddly . ....... ? but we know it uses that 2 pin primary connector plug you show , 2 different ring terminals & a 2-lugs YAKAZI junction box . All this i can say is confirmed tech. here ...... so far

- we still need the correct COLOR CODE's for each of the 4 fusible links wires , after that is verified 82627-60030 can be alive once again

- i cannot make out any of the original color codes of your links wires , there badly puffed up and charred from sacrificing themselves for the greater KCJ78 good ....

 

[TreadingLight]

I have used ToyotaMatt's links - they are indistinguishable from OEM.

Just get him the colors off your current wires (both the ones going into that black round connector and the two going into the black square box) and he can recreate the original link.

Recommend buying two so you have a spare.

 

[94KZJ78W]

hi ,

- my 90982-08187 i hand assemble using all oem japan spec. parts , is NOT also for your KZJ78 .......

- i did do a bit of digging deep into this topic , as it relates to this specific thread , and the LJ78 & KCJ78 Fusible Links assy. both shown above by different fellow members and there particular trucks have both unique part #'s as you can see the primary connector housings are very very different ....

- this being said as best i can determine your above needed KCJ78 Fusible Links assy. part # is 82627-60030 ........ ( should be )

- this is a disc. / nla part # ......

- there is no links wires spec's on the EPC microfiche oddly . ....... ? but we know it uses that 2 pin primary connector plug you show , 2 different ring terminals & a 2-lugs YAKAZI junction box . All this i can say is confirmed tech. here ...... so far

- we still need the correct COLOR CODE's for each of the 4 fusible links wires , after that is verified 82627-60030 can be alive once again

- i cannot make out any of the original color codes of your links wires , there badly puffed up and charred from sacrificing themselves for the greater KCJ78 good ....

Hi Matt...i actually ordered the replacement links through VintageTeqParts...which apparently you work for or own? I purchased the parts a few weeks ago but haven't shipped yet, can i get your contact info to see what's going on with the order? I've emailed several times, no response that i've seen. Not upset, just trying to get a status on the part...

Thanks

 

[ToyotaMatt]

Hi Matt...i actually ordered the replacement links through VintageTeqParts...which apparently you work for or own? I purchased the parts a few weeks ago but haven't shipped yet, can i get your contact info to see what's going on with the order? I've emailed several times, no response that i've seen. Not upset, just trying to get a status on the part...

Thanks

i will MUD PM you now here , please check your in-box , upper RH corner up MUD app/ desk top browser for a red ICON alert small box

thanks 1

 

[chap79]

- i was huntering into this topic last night pretty deep and i did come op with 2 different part #'s for a KZJ78

- this is the later of the 2 part numbers based the Round Connector you have there


- Toyota does NOT give any sort of Links Spec.s for any of the 78 series , which is VERY ODD too ?


- so , .........


- all we need to do now is correctly COLOR CODE ID each of the 4 fusible links wires , and where each color code goes from the main ring terminal on your Battery

- this is Eazy Peezy ........


- get some simple mineral spirts / paint thinner ......NOT Brake Klean ..!

- wipe each fusible wire after you pull down the FIRE PROOF cloth loom , the wires under it / them will be much more colorful and happy , wipe the area with the paint thinner on a cloth a bit .,..... PRESTO bright Colors once again

- i do have all the correct OEM Japan Spec. electrical service parts on-hand to Hand Assemble this particular Fusible Links set up correctly , by the FSM ...

i have not yet run across this exact one , so i have no Jigs or Nots or photos to refer to ..........yet


but that all will change by this evening hopefully , and the KZJ78 90982- will lived once again .........

- oh , recent update : ALL fusible Links i personally reproduce and hand assemble now will come with the Harness Side Male Connector Housing , plenty of extra Terminals and any / all OEM Updated Stainless Steel Special Locking Flange Nuts too ..........

.
thanks
Matt

.

Here’s the fusible link off my ‘94 KZJ78.

 

[chap79]

 

[ToyotaMatt]

View attachment 3887257 Here’s the fusible link off my ‘94 KZJ78.

,

Thanks !

excellent tech pics

only un-klear detail here is which color wire ring terminal goes on the larger and smaller male threaded studs on the black box above ?


it can and either one possibly , as it is on various other toyota and or land cruiser fusible links set up's


if you can show a photo below , i can'\t quite make out the black wire 1/2 ring exposed above ?

we never never guess or assume here in any way

always confirm and verify each and every day ...


/


Black wire =

Blue wire =

 

[chap79]

,

Thanks !

excellent tech pics

only un-klear detail here is which color wire ring terminal goes on the larger and smaller male threaded studs on the black box above ?


it can and either one possibly , as it is on various other toyota and or land cruiser fusible links set up's


if you can show a photo below , i can'\t quite make out the black wire 1/2 ring exposed above ?

we never never guess or assume here in any way

always confirm and verify each and every day ...


/


Black wire =

Blue wire =

Blue goes to small ring terminal.

 

[ToyotaMatt]

View attachment 3887660View attachment 3887661Blue goes to small ring terminal.

.

i am crafting this up real time live , ill post my completed work here on this now confirmed and verified KZJ78 Fusible links assy.


this is one i have never reproduced before , it will be a New addition with its also confirmed and verified original TOYOTA part # too

Thanks for the help on this !

a very special cereal-box prize of gratitude will be heading your way that is in lock step this Holiday weekend and your KZJ78 ...

matt