Fusible Link burned up...need help!

Click on the diagram to enlarge it to full size



Fuse links come with a current rating just like fuses. A clue as to what current they are designed for is to look at the size wire they protect.

Choose the fuse according to the wire size.

Wire size current table:
18 gauge wire = 5-8 amps
16 gauge wire = 10-12 amps
14 gauge wire = 15-17 amps
12 gauge wire = 20-25 amps
10 gauge wire = 30-40 amps
8 gauge wire = 50-60 amps.

Fusible link colors
Link Gauge Color
20 Gauge Blue
18 Gauge Brown or Red
16 Gauge Black or Orange
14 Gauge Green
12 Gauge Gray


Keep in mind that the wire size in the chart is for the circuit itself, not the size of the fuse link. The packages of fuse link repair material you can get at the auto parts stores also will have a current rating on them.

See Ford Fuel Injection How To Solder Like a Pro for some excellent tips of soldering wires for best electrical performance.

Aircraft type circuit breakers are designed for low voltage DC applications and would be an excellent choice to replace fuse links. They come as a push/pull to reset button, and range from 1.5 amps to 60 amps and higher.

See Pilot Supplies, Avionics, and Homebuilt Aircraft Parts from Aircraft Spruce and Specialty Co. or http://www.wicksaircraft.com/catalogDetails.php or Home for circuit breakers and other items.

There is a store local to Orlando that does electronic surplus and has all kinds of circuit breakers. See index That's where I get most of my wiring supplies. There may be a similar type store in your area.

Cut out the burned fuse link or wire and replace it. The yellow wire that connects the 4 links to the starter solenoid isn't a fuse link. You can replace it with standard 10 gauge wire from the auto parts store.

You will probably get to cut the rubber covered junction out to replace the damaged wire or fuse link. Strip the insulation off the cut ends and twist the stripped ends together to rejoin them. Be sure to solder the new wire or fuse link in place. See the link in my previous post to Ford Fuel Injection How To Solder Like a Pro for some excellent tips of soldering wires for best electrical performance.

Hmmm... can it be an epidemic?
I just had a 20GA link burn up on my 85 GT. Same place- starter relay switch (solenoid). Do you have a diagram for 85's?
How about availability? I've tried my local parts stores with no luck.

TRy NAPA Auto Parts for the fuse link wire. I have seen it at Advanced Auto Parts, but that was some time ago.

Checker used to have it in the wiring aisle as well.