For example, a 14-gauge wire would be protected by an 18-gauge fusible link; an 8-gauge wire would be protected by a 12-gauge link, etc. GM used fusible link wires in the charging system as well. Looks to be maybe 6mm^2 cable. They are placed in-line between delicate harnesses and large sources of electrical current in your carbetween the battery and alternator, for example. now my light is off. The ring terminals will be soldered on and heat shrinked with those SHCA heat shrinks. It's designed to fail before your wiring harness melts to goo. There is no designated alternator fuse on either fuse panel in the 2002 Chevrolet TrailBlazer; instead, You'll find a fusible link between the alternator and the battery, where they are directly wired together. After the 1980s, engineers started using the fusible link between a battery and an alternator . Also, check the battery cable connection at the TIPM, make sure it's clean and not loose. I ran a 6 gauge wire from the 105 amp alternator to the battery with a Cooper-Bussman 100 amp circuit breaker mounted under the battery tray. The reason for this is that there have been documented cases where internals in an alternator suddenly short out, even when parked. Battery lite is on and voltage accros battery is 12.4?volts. OD may be the same but wire diameter is smaller. Or check for voltage at the "B" wire at the ignition switch. So about a 1v drop between alternator and battery, this seems to high to me. Better component designs have reduced the need for fusible links, but they are very common in large current circuits connected . It will have power all of the time. Top Answer. Then again, in the last vehicle that I did a Big 3 on, I had a fusible link between the alternator and the battery, stock. Ford switched back and forth between fusible links and fuses more than once. As a general rule, a fusible link is made of wire that is four gauges higher (smaller) than the rest of the circuit, making it the weakest link in your electrical chain. It's been mentioned only a few times that I could find. It's called a fusible link. Well, it was all for security purposes. The gauge of the fusible link should be 4-gauges larger than the wire it is connected to. I'm reaching out to all Jeepers 'cause I'm sure you have one too. It should be in a box somewhere in the engine compartment. There is now no fuse there. Hey, new jeep owner here, I've got a 2002 wrangler, and it started throwing up a check gauges warning, and I noticed that the voltage was at ~12V. But the trend got changed. And everyone is right on here you need to check the fusible link. Match the fuse capacity to the alternator rating; for example, a 100 amp mega-fuse is good for a 95-amp 3G. Leave the rest of the wiring alone. wire from the battery to the alternator. As you probably know, there's not a lot of room under the hood of a C3 Corvette, and this wirealong with the fusible linkis part of the headlight harness, which places it between the brake booster and the windshield washer tank, ending on the firewall-side of the fuse panel. If an alternator is disconnected, due to an open fuse or fusable link, while under load, it will damage the alternator's diodes, due to a high transient voltage surge. Long story short, I had to replace the power cable between my battery and alternator and now rather than using a fusible link I have an actual fuse. You can get them at Walmart or any autoparts store. Nick B. January 22, 2021. Fusible Link between alternator and statrter or from battery to starter.. what guage is it suppose to be.. Posted by metalmethod6 on Apr 10, 2011. RJRENTON said: Alternator output connections to the vehicle's wiring system are not fused. Hey should I fuse between the alt and battery? Edit: I got a one foot length of 10 gauge comin' in from Amazon for just a few bucks, along with a custom bumper sticker and a K&N prefilter for 'Black Betty' That's the cable I have been working on and given reference above. The fusible link between alternator and battery. The first section is the green stripe cable you use for the earth on house wiring. Before about 1980, there were no fusible links on alternators, but after that it is common practice to have a fusible link between the alternator and battery to prevent fires and wire burning up in the unlikely event that someone installs a battery with the polarity reversed or if a diode in the alternator fails. Any time you upgrade your alternator, you should also strongly consider upgrading the gauge (size) of the wire that charges the battery as well as the fusible link in case of a short. Kettle Custodian (pot stirrer) What's the amperage capacity of the alternator? Alt > red/gray > black > a fusible link [white] > green > computer. They are pretty predictable and work okay, but modern fuses are more accurate. But the trend got changed. I'm using 4 gauge wire. Fusible links are usually two wire gauge sizes smaller than the wire they protect. GM has a 40 amp Mega fuse protecting the loads from the Auxiliary battery . It has two joins. In the production setup, the Megafuse holder was integrated into the side of the factory Distribution Box. Check that the connections at the battery, alternator, and remote voltage regulator are clean and tight. Sep 18, 2010. there IS a fuse between the alternator and the battery!!!!!! But when someone mentions the "alternator fuse", they're generally referring to the primary, high-amperage fuse (or fusible link) between the alternator and the battery. Re: Alternator fusible link blown. For example, a fusible link in a 10-gauge wire would be 14-gauge. When they are replaced, they must be about the same length as the one you are replacing. Normally the alternator to battery wire is a 10 ga wire. One fuse link, between the battery cable connection at the starter, and the ammeter, is all that's really needed. It went to the positive battery terminal . Apr 10, 2022. . Looks like the PO just connected the two wires together. 14+ at the alternator. No corrosion on the alternator cable connection to the bolt in the positive connection to the battery cables in the little red box. You should find and fix the short before replacing the link. The optional alt is 130A (2 holes), and it uses 2 gray fusible links. Jul 12, 2016. its not replacable though. Here is the solution, Main PNDB, Freightliner part number A06-72138-012; which is available for around $80; an alternative, if you want a simple battery disconnect switch, A06-72138-013-- (you can wire up a low voltage rocker switch in the cab and disconnect the battery remotely, pretty convenient, about $150 for that one). Odd number wire gauge sizes like 19, 15, 13, and 11 are counted when . That was the location of the blue and orange striped wire. From the alternator I'm palnning on running 8 gauge wire from the alternator to the battery and I'm thinking I'd rather use dedicated fusible link rather than take a chance. As far as the fusible link, it runs from the starter relay on the left inner fender to the alternator. Oct 28, 2017. 12.2 volts but drops quickly and takes a long time to recharge. Please consider creating a new thread. . Like any fuse, the primary alternator fuse acts as a circuit protection device. the usually blow once they get corroded enough o. its 75a. Yes No +1 Tuesday, February 21st, 2017 AT 10:17 AM KEN L Breeze sells the mega-fuse in a kit with a rubber capped holder. Only just 13 v at battery. Most all modern cars have one for the alternator. Coolerman SILVER Star Joined All my wiring under the hood will have tech flex insultherm which is good up till 1200 degrees. From what I've read, there is the 4-gauge rule. '08 F-250 CCSB Lariat 4x4 6.4L Auto. Consult your vehicle repair manual, if necessary, to locate the alternator fuse or fusible link. One advantage to this method of connection is that it's painfully obvious when the link is broken . Search Fixya . It is always hot. The wire from the alternator to the battery looks like a 4 or possible a 6 gauge wire depending on the thickness of the insulation. If you cannot get a fusible link, use a inline fuse holder. . Currently in the car is 100 amps. Here is a picture of a burnt fusible link and a replacement fusible link. (needle nose pliers or vise grips, 10mm & 8mm sockets, long thin flat head screw driver, fine tip sharpie) remove the cover and remove the bolt inside the black cover, this holds the fusable link to a main cable (probably the alternator cable). Losing 1/10th of a volt from resistance of the fuse or circuit breaker is not worth the risk. On white/red wire between the starter and the key switch. You can use a fusible link. The standard alternator for a '95 F150 is 95A (4 holes between each pair of ribs on the face), and it uses a single gray fusible link wire. After the 1980s, engineers started using the fusible link between a battery and an alternator. Alternator Wire Gauge Size Chart. The dark green wire is the fusible link. If you have a 100 amp alternator it will have a fat wire to charge the battery, but in a short situation the battery will dump several times that . As when the stock alternator is loaded way down, it can produce 160amps at about 12.8 volts. If you bypass this by hooking it up direct, then the whole harness may burn up. It is bonded (electrical splice 09) to the Black with gray stripe about one foot down the harness. Aug 10, 2009. ieee reference method for enclosed in conduit for such cables is around 50amps. Anyone know where the fusible link for the alternator sense wire is located on 2011 6.7? Add a fuse or fusible link to it. 04-01-2009, 04:12 AM. This is the cable which the alternator uses to deliver its charge to the battery. Ok so the wire from the positive post on the battery to the alternator corroded away. Check for a blown fuse or fusible link. Any other fuse of any type in the main charging system is simply a "belt and suspenders" approach to electrical circuits. First and foremost, check all the battery connections; and the alternator fusible link (a couple inches up the battery cable in a smaller cable attached to the main one) for corrosion or bad connections---that was a common problem area, especially for "up north" cars. To test the link, simply check for power on both sides. In a 130amp 3G the fuse should be a minimum 160amps, preferable 180 or 200amps. Top. Want Answer 0 . check the fusible links. Double check the connections to the battery, if it is loose, the volts might show low. Fusible link wire is color-coded. It goes to the alternator using a black/gray wire. The RED wire under the larger bolt at the alternator is cabled DIRECTLY to the battery (thru an inline fuse. Fusible Link between alternator and statrter or from battery to starter.. what guage is it suppose to be.. - Chevrolet Astro question. by Steve83 Thu Dec 23, 2010 4:59 pm. [aka Fusible-Link] ) From your description, the ONLY fuse you could have 'blown' is the one I just described above. Bigchuck, May 29, 2012. you could run a wire from there to the battery but that doesn't explain what went wrong in the first place Posted on Feb 11, 2013 Not Helpful Comment Ad Add Your Answer I PUT A NEW ALTERNATOR AND BATTERY IN A 1999 FROD . . Thank you johnw777. Oh well. It starts off gray in color, reaches the link, and then turns to black with an orange tracer to the alternator. What the fuse might offer is a degree of protection against wiring burnout if the battery or main cables on one side of the isolator become short-circuited, and the battery on the other side dumps a heavy current through it. the fuse is between the starter and the alternator. Which fuse is for the alternator? mechman told me not to due to probable voltage drop across the fuse. There is another fusible link between the alternator and the computer. . Feb 28, 2006. thanks . If you find one of these links and it does not have power on both sides, that is the faulty . General Guidelines for Fusible Links. A 95A alternator is unlikely even to be able to blow a 100A fuse, which might take hours to react at 130A. It take very little time for a 90A alternator to fully charge an 80AH starter battery, and the split relay connects the cabin batteries anyway. well it happened at the fusible link. If you install a 4ga wire from the alternator to the horn relay and leave the 10 ga from the relay to the battery and have a short in the alternator the 10ga wire will in efffect become a fusible link and likely melt between the horn relay and the starter, possibly causing a fire. Go look at the wire on the battery terminal of your alternator. Not very old battery started to struggle. Plug and play installation vs cut and splice. The cable goes from the alternator to the battery. A gauge of wire 2 sizes smaller than the rest, typically 6" in total length. (BTW, misspellings don't help the search effort!). The protection is not from some damage but from catastrophic electrical fire that can't be put out. A piece of wire with high temp insulation is cheap. to the battery. Fuse links are all down at the starter,might be worth checking. Hope that fits with your replacement link and is some help. A 4 ga wire would nominally be protected by an 8 ga fusible link. . wihaltom. This will take care of any over-current conditions and it's reset-able. #12. subzali said: So I think this is where a fusible link is supposed to go - between the battery and the wiring harness. :sm_party: 1 - 6 of 6 Posts. The alternator to passenger battery cable is a fusible link. The chart below charts the gauge wire required based on alternator amperage output and length of wire. and what you need. If there's 0 resistance, then you know the fusable link hasn't blown. I would run [piggyback] one wire of the same size as the car has now [#10 or #12] from the battery to the alternator stud. I don't have voltage on that wire and found the place on the wire where it rubbed through the harness at, but I think the fusible link may be blown because of it. Exactly as FMT said, there is a reason the fusible link burnt up. 2004 ranger 4.0 engine read more i replaced the whole wire with a new 6ga. Fri Apr 15, 2011 2:20 am. These links must transmit high-current electricity, but also protect the rest of the electrical system from dangerous spikes that could cause a fire. If you have no power via the yellow wire with a white tracer, check fuse 17 in the under-hood fuse box. There are 2 fuses for the alternator. The smaller-gauge wire handles less current . by grayslater. I checked the fuse-able link, and several other things I had googled, and never could find out if the alternator has a conventional fuse or not. Not sure who told you this but the fusible link you are looking for is b/t your battery and alternator. '99 CV, '94 CV, & two '96 EB Broncos RIP. I've searched all through this forum for information on the fusible link between the alternator and PDC. add the two joins of unknown quality and I'm not surprised there is a 1v drop. Assume you are talking about a mega-fuse for the alternator circuit. are you having battery charging issues but have changed the battery and alternator? One way to 'test' this fuse is to use meter to check for 'battery voltage' at the alternator where this red wire connects. Is there a fuse in the charging link? As a result, I put a circuit breaker on my "Big 3" charging wire. MartyS. Above: The photo shows the location of the wire and . Charged state not dead, but always a bit low. This is an older thread, you may not receive a response, and could be reviving an old thread. Everything is your car should be fused except the main positive battery cable to the starter. Jun 6, 2009. Your battery is showing 11.5 volts which is low. You can replace the fusable link with regular battery cable, but make sure you place a fuse close to the alternator, and I'd recommend an ANL fuse in the 130-140 range as our alternators put out max ~130W. Disconnect the power plug from the alternator, check the resistance between that connector (one of the 10awg black w/orange stripe wires) and positve battery cable. New battery and alternator installed. Images (Click to enlarge) SPONSORED LINKS Was this answer helpful? 4. What size fuse should I be running? Sounds like the alternator is trashed. an entire new cable is required. If the alternator fusible link is corroded it will not charge properly. Voltage at battery still 12.4 volts. Jan 8, 2010. A fusible link is required between the alternator and the battery. Do the tests described in the section "Troubleshooting for Unusual Charging System Voltage Drops" below. Such a wire would be protected by a 14 ga fusible link, at the solenoid/battery end. The wire with the yellow butt splice appears to be the original fusible link that burned out once and was repaired by splicing. Post. I do not know where this link is located. REMY QUICK TECH TIP: TA-017 (Burned fusible link between the alternator and the starter solenoid)and that's another reason why your next starter or alternat. 2004 3500 4x4 SRW QC - 48RE self built @ 202K with lots of goodies - HE351CW, S&B CAI, 08 front clip, Edge Juice with Attitude CTS2, Silverline 4" exhaust, Cometic Gskts Your ammeter should read one half of the current going into or out of the battery. the 98~2001 Explorer used a 130A alternator and had a 175A bolted Megafuse for the cable between the battery and alternator. Technician A says that if a fusible link in the alternator charging circuit is replaced with standard sized automotive wire, the circuit will be unprotected Then again, in the last vehicle that I did a Big 3 on, I had a fusible link between the alternator and the battery, stock Volvo 940 Coolant Temperature Sensor Mechman 1999-2007 Ford Power . Well, it was all for security purposes. "About the fusible link in the alternator/battery cable assay. According to the manual there's a fusible link between the alternator and the starter at splices s101 and s150 (see below). The fusible link is located between the battery and the fuse/breaker box. It also means a shorter connection from the alternator to the heavy starter wiring back to the battery, less volts drop which can be considerable with high output alternators. One is usually a fusable link (wire) for connecting the stator diodes to the battery, and a lower value fuse (10 to 30 amp) for protecting the field (rotor). Thanks for saving me $2475.99 from my local jaguar dealership. Jan 19, 2018. IMO your main problem now is that you've used huge wire to connect your alternator to the battery. G. Chad; For a non turbo 2006 PT. Mounts conveniently on the inside of the F-panel. Example 10ga. If a starter blows a winding or an alternator shorts a diode, the fusible link can prevent a fire. One wire is 4 ga and it is red color. Before you changed the fusible link did you have these issues: while driving the battery light comes on then comes off after a while (usually no longer than 5 mins); when at a stop the idle drops really low and the battery light turns on and sometimes idles so low the car dies but starts back up very easily; when car turns off all accessories such lights, blower fan, dash lights, etc., still . If there is not battery voltage at the alt. Not your alternator and starter. One would be foolish to believe there was no protection built in to a vehicle's charging system. I have the shaker 1000 if that makes any difference. In the early days, more precisely- before the 1980s, you would not find any fusible link between the alternator and the battery. A bit of sleuthing with a multimeter turned up that the fuse between the alternator and battery is blown, the alternator's end of the fuse reads 26V while the battery's end reads 11.5V. When there's excessive current flow, the fuse blows to prevent a circuit overload that . What color is it? Good time to upgrade to a 3G. There is green fusible link mounted to the large starter lug. As an example. Older cars used a "Fusible Link" wire between the alternator and battery, because 100 amp fuses were expensive. This varies from alternator to alternator and is much higher for high output alternators. wire requires a 14 ga. fusible link. Typically, a given harness segment is protected by a fusible link that is four gauge numbers smaller. Here are some tips. A fusible link is nothing more than a wire that will burn and fail if too much current flows. My alternator is 135 amps. In the early days, more precisely- before the 1980s, you would not find any fusible link between the alternator and the battery. the cable that comes off the battery goes to the starter and continues to the alternator and is one solid cable (with the exception . is this a problem? There are three wires coming off the alternator. Fusible links don't melt-down unless there is a short, and they are usually easily spotted by checking for a burnt spot and loss of continuity in the wiring harness. checked voltage with engine running at food speed (2000rpm). If the battery has a bad cell, which can happen from a manufacturing defect or improper charging, it might show low. This is an older thread, you may not receive a response, and could be reviving an old thread. prussakolep. If the battery is not fully charged, the volts maight show low. Good continuity on each end of that fuse-able link. The fusible link between alternator and battery. Before replacing the fusible link, I would check the continuity of the wiring from the battery + to the "B" wire at the ignition switch. In our cases in the fuse box, often at the battery pos+ terminal.

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