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Ok I was driving on the highway and just realized I never re attached my fan shroud and looked down and seen the temp guage sitting higher than usual at 190 and instantly shut down again, pulled over poped the hood and found the same wire broke AGAIN! Re attached it and same frigging thing, fortunately the module is under warranty, but why does this keep happening could the starter solenoid be defective? It's like that wire is drawing too much current and gets soo malleable it brakes, could there be a problem with the solenoid?
MSEE
Joined: Apr 2004
Posts: 10,386
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From: Austin, TX
The solenoid has nothing to do with the fusible link that keeps breaking. The solenoid only serves as a mounting point to connect the positive battery cable and the main feed to the truck's electrical system.
Something in your truck's wiring is shorting out and collapsing the fusible link. Has this truck's wiring been modified significantly? There are few things in the truck that can cook a fusible link without blowing a fuse, assuming the truck is wired as original and all fuses are at the correct rating.
You'll have to go through all wiring you can see (including behind the dash) and look for frayed or pinched insulation. I assume the item that keeps dropping is a fusible link, correct? What AWG is it?
Something in your truck's wiring is shorting out and collapsing the fusible link. Has this truck's wiring been modified significantly? There are few things in the truck that can cook a fusible link without blowing a fuse, assuming the truck is wired as original and all fuses are at the correct rating.
You'll have to go through all wiring you can see (including behind the dash) and look for frayed or pinched insulation. I assume the item that keeps dropping is a fusible link, correct? What AWG is it?
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The fuseable link isn't breaking it's the wire itself were it connects to the solenoid, maybe it's just soo old it's melting apart because it can't handle the amount of current it's rated for anymore?
MSEE
Joined: Apr 2004
Posts: 10,386
Likes: 35
From: Austin, TX
I am assuming your original fusible link is still attached and this is what you're re-connecting. Please post a picture of exactly what you're seeing and what you're doing so that I can be sure we are on the same page.
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Yes it is the original, maybe I can clarify myself a little, it's not breaking the way a fuseable link usually does "at least to my experience" it's breaking right at the eye connector that gets bolted to the solenoid, maybe I just keep damaging it when I crimp the connectors on
MSEE
Joined: Apr 2004
Posts: 10,386
Likes: 35
From: Austin, TX
Thank you for the update. You won't be able to reliably crimp a new eye terminal to the end of a fusible link because the strands are too thin. You will need to cut out the fusible link completely (at the factory splice) and install a new fusible link. The replacement fusible link will already have a new eye terminal roll crimped to the end. You can then connect the fusible link to your truck's main power feed by soldering and shrink-wrapping the connection.
Fusible links are available at most parts stores. A fusible link must be sized two sizes below the wiring it is rated to protect (for example, use a 14 AWG link to protect 10 AWG wiring). If your original link still has the rubber label, replace it with what the label says.
Fusible links are available at most parts stores. A fusible link must be sized two sizes below the wiring it is rated to protect (for example, use a 14 AWG link to protect 10 AWG wiring). If your original link still has the rubber label, replace it with what the label says.
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