What does the fusible link do?

A fusible link is a short piece of insulated low-voltage cable within an automotive wiring harness that is designed to protect the harness in applications where a fuse is unsuitable.

What happens when a fusible link blown?

When it fails, it will break the continuity in the rest of the circuit, preventing damage to other components down the line. A fusible link typically costs a couple of bucks and can be replaced in 30 minutes.

Can a wire be replaced with a fusible link?

Once located, you can replace it with a fusible link that matches the gauge of wire called for by the original design.

Can a bad battery cause an alternator to over charge?

Make sure that all the connections to the alternator, remote voltage regulator (if applicable) and battery are clean, tight and in good condition. Check your battery or have it tested at your local auto parts store. A bad battery cell can cause the alternator to over-charge the good battery cells.

What happens when the conductor of a fusible link melts?

In an extreme current overload situation, the link’s conductor is melted while the ensuing flame and spark are contained within the link’s insulation. A dead, shorted alternator on the interstate could have burned our car to the ground if it wasn’t for the Fusible Link.

Where to look for fusible links on a car?

When fusible links fail, they often lead to a no-start condition. On an older vehicle, the first place to look for these links is under the hood near the battery or along the firewall — look for a length of wire that is roughly two gauges smaller than the harness it’s connected to.

What size wire for 100 amp alternator?

Generally, they recommend an 8-gauge wire for our 100 amp alternators and step up to a 6-gauge if the battery is in the trunk so there is no power loss. A 140-amp unit should use a 6-gauge wire, and 4-gauge to the trunk; 200-amp units should have a 4-gauge wire and a 2-gauge to the trunk.

What gauge wire for alternator?

Tuff Stuff recommends an 8-gauge wire for its 100-amp alternators, and a step up to a 6-gauge wire if the battery is in the trunk. A 140-amp unit should use a 6-gauge wire, and 4-gauge to the trunk.

What size fusible link?

A fusible link is similar to a fuse, it is a type of circuit protector. It is a length of wire typically 6 inches long and usually two gauge sizes smaller than the wire it is protecting. If excessive current runs through the circuit, the wire overheats and melts, breaking the circuit.